Overall Detailed MS - T316 - R00

CONTRACT T316
Outline Method Statement
Table of Contents
Introduction ............................................................................................................................... 4
General ............................................................................................................................. 4
Project Site Location ......................................................................................................... 6
Scope of Works ......................................................................................................................... 7
Mobilization Plan ..................................................................................................................... 13

General ........................................................................................................................... 13
Resource Arrangement ................................................................................................... 13
Mobilization of Personnel and Equipment ...................................................................... 14
Temporary Site Offices and Facilities ................................................................................... 15

Site Access ..................................................................................................................... 16
Site Utilization Plan ......................................................................................................... 16
Traffic Control.................................................................................................................. 16
Detailed Traffic Control Plan ........................................................................................... 17
Implementation of Traffic Control Plan............................................................................ 17
Coordination with Relevant Authorities ........................................................................... 18
Site Establishment .................................................................................................................. 19

Pre-Condition and Post-Condition Surveys .................................................................... 19
Traffic Diversion .............................................................................................................. 19
Utilities ............................................................................................................................. 20
Trees Protection .............................................................................................................. 25
Site Hoarding and Access Control .................................................................................. 29
Site Setting Out ............................................................................................................... 30
Ground Improvement .............................................................................................................. 32

General ........................................................................................................................... 32
Ground Improvement Location ....................................................................................... 33
Improvement at Different Types of Ground .................................................................... 34
Jet Grouting..................................................................................................................... 35
Underground Infrastructure Building .................................................................................... 48

General ........................................................................................................................... 48
Construction of Underground Infrastructure Building...................................................... 49
Protection and Diversion of Existing Utilities .................................................................. 51
Site Clearing???.............................................................................................................. 54
Ground Water Control ..................................................................................................... 55
Ground Improvement (Station) ....................................................................................... 56
Diaphragm Walls and Barrette ........................................................................................ 56
Tender Documents Page 1 of 225

CONTRACT T316
Bored Piles at the Proposed Station and Entrances....................................................... 57

Excavation Method for Station ........................................................................................ 58
Concrete for Station and Entrances ................................................................................ 65
Fabrication and Installation of Steel ................................................................................ 75
Instrumentation and Monitoring ...................................................................................... 86
Protection to Adjacent Buildings or Structures ............................................................... 86
Flood Prevention Measures - Station ............................................................................. 90
Noise Enclosures and other Equivalent Noise Abatement Measures ............................ 95
Plans and Proposals to adopt Labour-Efficient Construction Methods ........................ 102
Construction Equipment to be deployed ....................................................................... 105
EPB TBM Bored Tunnels ...................................................................................................... 114

Introduction ................................................................................................................... 114
Tunnel Organization & Responsibilities ........................................................................ 115
Geological Profile .......................................................................................................... 117
Tunnel Work Flow chart ................................................................................................ 118
Site Establishment ........................................................................................................ 119
Ground Improvement (Tunnel Alignment) .................................................................... 123
Launching Shaft ............................................................................................................ 124
TBMs Assembly ............................................................................................................ 124
Bored Tunneling Works ................................................................................................ 129
TBM Disassembly ......................................................................................................... 159
Risk Mitigation ............................................................................................................... 165
Muck Removal System ......................................................................................................... 173
Resources for Tunneling ...................................................................................................... 176

EPB Type Tunnel Boring Machine ................................................................................ 176
Project Reference of TBM Supplier .............................................................................. 177
Plant and Equipment ..................................................................................................... 178
Tunnel Segment Lining ................................................................................................. 178
Cross Passages and Shafts ................................................................................................. 192

Introduction ................................................................................................................... 192
Pre-Excavation Works Procedure ................................................................................. 192
Construction Procedure ................................................................................................ 193
Installation of Temporary Support ................................................................................. 194
Wire mesh, Shotcrete and Lattice Girder ...................................................................... 194
Typical Construction Sequence for Cross Passage ..................................................... 196
Typical Construction Sequence for Cross Passage Shaft ............................................ 199
Temporary Support/ Retaining Wall at Cross Passage Shaft ....................................... 200
Proposed Equipment and Anticipated Cycle Time ....................................................... 206

CONTRACT T316
In-line sump pit at Bored tunnel .................................................................................... 206
Details of the Proposed TBM to be deployed ..................................................................... 208

Technical Presentation of the Proposed TBM by CREG .............................................. 208
Technical Presentation of the Proposed TBM by NFM ................................................ 216
Attachment ............................................................................................................................. 225

CONTRACT T316
Introduction
General
Daewoo Engineering and Construction Company also known as “the Contractor” prepared this
method statement for Land Transport Authority’s (LTA) call for tender of Contract T316 –
Construction of Underground Infrastructures. This method statement will narrate a summary for the
whole works followed by series of detailed statement of the major work items as mentioned in the
Instructions to Tenderer (ITT) Appendix A.
The Contract T316 includes the construction and completion of Underground Infrastructures and
Bored Tunnels from Changi Aiport Terminal 5 (T5) development towards Terminal 2 (T2) including
eight (8) cross passages and the associated ancillary works.
The TBMs for bored tunnels shall be driven from a launch shaft at Changi Airport Terminal 5 that will
go through Underground Infrastructure Building that will run in close proximity with Changi Airport
properties and be driven continuously until breaking in at Terminal 2 (T2).
After completing the bored tunnelling works, the Contractor will retrieve back all TBM parts back to
the TBM launch shaft at Airport terminal 5.
There are optional activities in which the Contractor when exercise, shall be subjected to the same
requirements as mentioned in the Particular Specification.
Option 1: To omit the Design and Construct Underpinning Works at T2 North Finger Pier
Within the Option 1, the design and construction of underpinning works to facilitate the future
tunnelling works under T2 North Finger Pier, including instrumentation and monitoring, relocation of
plant rooms, utilities and road diversions and ground improvement works are to be completed in
accordance with the requirements of Appendix B of the Particular Specifications and if this Option is
exercised.
If the Contractor exercise this Option 1, the design and construction works at T2 North Finger Pier
will not be required.
Option 2: To Design and Carry Out Bored Tunnelling from E5 Aircraft Stand to Changi Airport
Terminal 2 Overrun Tunnels
Within this Option, the Contractor shall carry out design and tunnelling works (including Cross
Passage 1) from ES Aircraft Stand towards Changi Airport Terminal2 overrun tunnels. The
Contractor shall also carry out fitting out works to the facility building in accordance to the Drawings
and Appendix X1 of the Particular Specifications.
If Option 2 is exercised, the Contractor will not dismantle the TBM but shall maintain it and its
associated accessories at the ES grout block throughout the duration of underpinning works before

CONTRACT T316
launching the TBM drive from ES Aircraft Stand to Changi Airport T2 overrun tunnels.
Option 3: To Construct Shaft at E5 Aircraft Stand
Within this Option, The Contractor shall construct a shaft and its associated grout blocks at the E5
Aircraft Stand in lieu of the original docking grout block provision stipulated under Clause 18 of the
Particular Specifications.
If Option 3 is exercised together with Option 2, the Contractor will not dismantle the TBM but shall
maintain it and its associated accessories within the shaft at E5 Aircraft Stand throughout the duration
of the underpinning works. The scope of works under Clause 18 of the Particular Specifications shall
be read in conjunction with Appendix X2 of the Particular Specifications.
Option 4: To Extend Defects Liability Period and Warranties for the Works
Within this Option, the Contractor shall extend the period of the Defects Liability Period and
warranties for the Works up to year 2037 for the caretaking period as detailed in Clause 17 of the
Particular Specifications and subsequent connection to upcoming Changi Airport T5 development.
If Option 4 is exercised, the Contractor shall commence preparation for timely submission of the
required documents.
The Contractor, in general, will be using conventional construction techniques and equipment
consistent with other similar projects in Singapore. This will include the use of specialized
pressurized-face Tunnel Boring Machines (TBMs) to excavate the tunnels. The construction
would follow all applicable local laws and international laws recognized by the country for building
and safety. Standard construction methods would be used for traffic, noise, vibrations and dust
control, consistent with all applicable laws.
The construction methods to execute the major works of Contract T316 is briefly described in this
document and will be subject for review and comments by the Project Manager subsequent to
contract award. The project team will further develop a detailed method statement prior to
commencement of works.
The construction methods explained in this document are for tender stages only and amendment will
be made after award of contract. Actual geological and geotechnical conditions encountered on site
during the progress of works may likewise act as catalyst for changes and revision of this method
statement to suit the actual site conditions and requirements.

CONTRACT T316
Project Site Location
Figure 1: Site Location Map

The Contract T316 is located from Changi Airport compound (Airside and Landside) and extended
to the existing operational Changi International Airport Terminal 2 Building, crossing under Runway
2 and Changi Coast Road integrating with the future Ground Transport Centre and Terminal 5 Station.

CONTRACT T316
Scope of Works
The Scope of Works under Contract T316 is described in Clause 2 [Scope of Works] of Particular
Specification which includes, but is not limited to, the design (where applicable), construction and
completion of the following:
a). Construction of an underground infrastructure, a launch shaft and 1.8km bored tunnels
from Changi Airport Terminal 5 (T5) development towards Terminal 2 (T2) inclusive of
cross passages;
b). Construction of underground infrastructure including all civil, structural, architectural,

plumbing, water services, roadwork, drainage, plumbing and sanitary, sewer, earthworks
and reinstatement works, ventilation shafts, approaching slab and other structures and
facilities, unless otherwise specified;
c). Design, build and maintain earth retaining or stabilizing structure (ERSS) system for
underground infrastructure and underground geotechnical work for cross passages, tunnel
sumps and adits;
d). Design for the shaft at E5 Aircraft Stand. The design shall also take into consideration for
the retrieval of the TBM;
e). Removal of Reinforced Concrete piles, if any, at collector drain to facilitate the construction
of underground infrastructure;
f). Engage an aerodrome safety specialist with good knowledge of International Civil Aviation
Organisation (ICAO) Annex 14 and CAAS Manual of Aerodrome Standard (MOAS)
requirements, preferably with Changi Airport experience, as approved by Changi Airport
Group (CAG). He shall be proficient in aerodrome standard requirements, aerodrome
safety and operation experience. His job scope shall include but not limited to the
followings:
i) Advise and assist in the development and implementation of Aerodrome Safety

Plan;
ii) Prepare aerodrome hazard identification and risk assessment for works within air/
near aircraft stand/ taxiway/ taxilane/ runway, including runway/ taxiway / taxilane
strips, runway end safety areas, approach light area, perimeter road, etc.;
iii) Prevention of incursion to aircraft movement areas;
iv) Obstacle and wildlife management;
v) Development of training and written procedure in relation to aerodrome safety;
vi) Conduct a Risk Assessment (RA) workshop covering aviation safety risk inputs

CONTRACT T316
from CAG, CASS and all its stakeholders;
vii) Prevent Risk assessment in the CAG/CAAS monthly safety working committee
meeting for further review and/or at any other forum where necessary prior to the
commencement of the work.
g). Design and carry out traffic road diversion works including Traffic Impact Assessment
(TIA);
h). Installation of ground improvement along bored tunnel alignment at cross passages and
for Tunnel Boring Machine (TBM) dismantling. The required minimum strength, stiffness,
and thickness of the ground improvement are shown in the Drawings;
i). Removal of H-piles along the 3 cell box culvert, if any, such that the Contractor’s Works
are not affected;
j). Take extra caution when working in the vicinity of Jet Fuel Pipelines;
k). Design and construction of underpinning works, including instrumentation and monitoring
of T2 North Finger Pier;
l). Prior to the underpinning works, the Contractor shall also:
i) Design and construct temporary buildings to house the temporary services for all
necessary equipment such as the specified chiller plants and water tank in the T2
North Finger Pier which shall be relocated from their existing locations;
ii) Design and carry out relocation of existing plantroom/equipment/services within

T2 North Finger Pier which is effected by the underpinning works;
iii) Design, install and regular maintenance of a new airconditioning system to serve
T2 North Finger Pier and the decommissioning, dismantling and temporary
storage of the existing Air Handling Units (AHUs), all these works are deemed
included in the Contract Price;
iv) Dismantle and replacement with new Passenger Loading Bridges (PLBs) as per
CAG’s requirements, if necessary, such that Works are not affected;
v) Divert all other existing services and utilities affected by this works; and
vi) Carry out associated reinstatement works upon the completion of the
underpinning works.
m). Design and carry out utilities (excluding Jet Fuel Pipelines), drain and road diversions
including reinstatement encountered around the T2 North Finger Pier and aircraft stands
and/or affected by the Works;

CONTRACT T316
n). Design, coordinate and construct underpinning and ground improvement works around
the T2 North Finger Pier and E20 aircraft stand;
o). Remove knock-out panels and connect, and construction of all waterproofing systems, at
the interfaces with Airside Road Connections (ARC);
p). Caretaking from Completion of whole of the Works to ensure that the underground
infrastructure and bored tunnels are in good condition upon handover of the Works as
deleted in Clause 17 of the Particular Specification;
q). Surveys, ground treatment, settlement risk analysis, settlement prediction, preventative
and corrective actions, all in relation to ground movements as detailed in Clause 14 of the
Particular Specifications;
r). Provision of first stage concrete in the trackway within the bored tunnels;
s). Design, build and maintain the Engineer’s offices in accordance with Clause 5 of the
Particular Specification;
t). Design and build, operation and maintenance of groundwater control system including
recharge wells to control the groundwater drawdown and relief wells to control the
hydraulic uplift.
u). Design and construction of temporary access roads and footpath to work sites and offices;
v). Waterproofing to the underground infrastructure, cut and cover tunnel interface, mined
tunnels for cross passages which interface with adjoining bored tunnel sections, tunnel
sumps and all other subsurface structures;
w). Design and build, repair and replacement of all boundary walls, fencing, gates, accesses,
buildings, facilities, driveways, etc. of the adjacent properties affected by the Works
including its maintenance, removal and final reinstatement to the acceptance of the
Engineer and/or CAG;
x). Temporary and permanent diversion of all affected existing utilities, sewers, drains and
box culverts excluding those to be diverted by the Authority as stated in Clause 16 of
Particular Specification. The Contractor shall lead, coordinate and liaise with utility
agencies and/or CAG and allow in his programme for the implementation of temporary
and permanent diversion including those to be diverted by the Authority;
y). The Contractor shall carry out investigations to identify all other existing utility services
within the vicinity of the Works. The Contractor shall coordinate with the relevant
authorities, utility agencies, and/or CAG, and design and implement temporary or/and
permanent diversion, or provision of supports of these utility services as appropriate and
as agreed with the authorities, utility agencies, and/or CAG and other interested parties,

CONTRACT T316
at his own costs. Works shall include but not limited to the coordination with the authorities,
utility agencies and/or CAG and reinstatement of utilities/services that were temporarily
diverted out;
z). The Contractor shall bear the cost for any subsequent diversions required to suit his
construction works. The Contractor shall make reference to Clause 16 of the Particular
Specification for these works;
aa). The Contractor shall be responsible for supporting and protecting the utilities that may be
affected during the course of construction, including any diversion as required by the
authorities, Utility Agencies and/or CAG. The Contractor shall coordinate and submit the
details and method statement to the relevant authorities/ agencies and/or CAG for
approval prior to the construction. The supporting structure has to be designed and
endorsed by a Professional Engineer with the Engineer’s acceptance prior to consultation
with the Utility Agencies and/or CAG;
bb). Design and build temporary drainage system and obtain acceptance from the Engineer
and approval from PUB and/or CAG;
cc). Reinstatement of drainage elements affected by the Works in accordance to the

Authority’s Drawings;
dd). Coordinate, supply, installation, testing and commissioning of all signage including road
and traffic signage;
ee). All necessary protective measures and works to existing buildings/ structures/
infrastructures/ utilities;
ff). Protection works and close monitoring of all surface and sub surface structures, buildings
and utilities along underground infrastructure, bored tunnels and within the zone of
influence to ensure that no damage occurs to these structures and services. Risk
assessments to be carried out in accordance with Appendix A of the General
Specification;
gg). Comprehensive pre and post construction condition survey of existing airport runways and
taxiways, existing aircraft stands, existing passenger loading bridges, existing structures,
existing drainage, road structure, flood lights, ancillary structures and properties etc., all
within the minimum zone of influence of the Works as identified in Appendix E of the
Particular Specification. Works shall include any interim repair works to existing
structures and properties affected during the course of construction;
hh). Coordination, supply and installation of Architectural works, finishes for underground
infrastructure and associated structures, unless otherwise stated;

CONTRACT T316
ii). Coordination, supply and installation of ironmongery including temporary cylinders and
temporary master key system, unless otherwise stated;
jj). Coordination, supply, installation, testing and commissioning of water services, sewerage
& sanitary systems, drainage systems for tunnels and underground infrastructure;
kk). Cordination, supply, installation and testing of lifting and pulling facilities (e.g. overhead
runway beams, eye bolts, lifting hooks, pulling hooks, lifting beams and chain blocks and
the like) including providing the necessary Ministry of Manpower (MOM) lifting appliance
certificates to the Engineer;
ll). Coordination with Trackwork System Wide Contractor and provide temporary continuous
sleeving from ground to tunnel level, including sealing up and making good after use, for
Trackwork System Wide Contractor to deliver concrete;
mm). Design, construction, implementation and maintenance of a feasible temporary traffic

diversion and traffic management scheme to suit his Works including all associated
ancillary works and the required safety measures, acceptable to the Engineer, CAG and
the relevant authorities, to facilitate the construction of the Works. The Contractor shall
obtain the clearance and approvals from the Authority, and/or CAG for the traffic diversion
and traffic management schemes prior to implementation on site;
nn). Design, construction, implementation and maintenance of the required associated

temporary drainage schemes until the completion of the Contract. The Contractor shall be
responsible for all authority and/or CAG approvals for the proposed temporary drainage
schemes prior to implementation;
oo). Landscaping and external works, relocation and reinstatement works in accordance with
CAG's requirements. The Contractor shall coordinate with all relevant authorities,
agencies and/or CAG to reinstate all affected external works, landscape and turf at his
own cost;
pp). Reinstatement of all affected landscaping by the Works to the satisfaction of the affected
stakeholders;
qq). Provision of necessary attendance to all the relevant Qualified Persons (QP)
(Architectural, Civil and Structural, Mechanical, Electrical, Supervision), Accredited
Checker (AC) and in-house QP(D) such as provision of drawings, calculations and other
documents required by QPs, AC and in-house QP(D) to carry out their statutory and
contractual duties;
rr). Coordination and provide all necessary provisions and attendances with all Interfacing
Contractors in accordance with the requirements as stated in Clause 7, Appendix A of
Particular Specification and Appendix L of General Specification;

CONTRACT T316
ss). Coordination with in-house QP(D) to ensure that the designated routes are adequate and
safe for the delivery and future removal of the equipment for the underground infrastructure;
tt). Coordination with in-house QP(D) for supply and fixing of all penetrations, openings,
sleeves and other provisions for all the SWC services in underground infrastructure and
tunnels;
uu). Construction of manholes, inspection chambers, sumps and chambers pits and laying of
services pipes and ducts as shown on plumbing and drainage, E&M and utilities Drawings,
which included sewer, water main and telecom, etc.;
vv). Coordination, supply, installation, testing and commissioning of earthing systems at the
underground infrastructure;
ww). Coordination, supply, installation, testing and commissioning of the lightning protection
system at the underground infrastructure;
xx). Design, coordination, supply, installation, testing and commissioning of the equipotential
bonding;
yy). Coordination and preparation of Pre-final and Final Design and As-Built Coordinated
Combined Services Model {CCSM) and Structural, Electrical & Mechanical {SEM}
Drawings for tunnels and underground infrastructure, in accordance with the Building
Information Models {BIM) specification;
zz). Coordinate with the E&M interfacing parties and comply with the requirements of BCA
Green Mark Gold;
aaa). Design, coordination, provision, construction and maintenance of associated temporary

structures and provision of temporary lighting and ventilation, security services, cleaning
services, temporary drainage system with earth control measures. The Contractor's
provision shall be in accordance with Chapter 17 of the Particular Specification; and
bbb). Provision of necessary Public Relation services as stated in Clause 4 of the Particular
Specification.

CONTRACT T316
Mobilization Plan
General
The Mobilization Plan will indicate how the contract will move from close of contract to service
commencement date.
The Contractor will prepare a fully developed and detailed Mobilization Plan. This will take account
of the particular structure of the Contract where the Planned Service Commencement Date occurs
several years after Contract signature.
The Contractor will exert the utmost effort to ensure the smooth and efficient implementation for the
mobilization of necessary resources to site as per schedule to tackle for the timely execution and
completion of the project.
The Contractor will immediately clear and level, if required, the designated site area to allow
installation and construction for the temporary facilities such as field offices, laboratory, laydown yard,
workshops, fabrication yard and others.
Earth moving equipment to be utilized on the above clearing and levelling works, i.e., excavator,
loader, bulldozer and dump trucks shall be deployed to site with maximum priority during mobilization
period.
The Contractor will carry out the mobilization activities in close consultation with the
Authority/Engineer based on construction schedule.
Resource Arrangement
Immediately upon receipt of the Notice to Proceed, the designated Project Management Team
headed by the Project Manager which is composed of key construction personnel will embark for the
project site to execute their respective work of duty for mobilization activities.
The team will make further investigation of the site and prepare a practical construction organization
design loaded with resource requirements.
The major tasks to be carried out by the project management team during mobilization period are as
follows:
To review the contract documentation and data and establish the detailed requirements
specific for the project.
To prepare the detailed work schedule of bar-chart format based on the given preliminary
construction schedule. This work will include the milestone dates, critical path and float
periods.
To finalize the general layout of the job site facilities, i.e., precast and general fabrication

CONTRACT T316
yards, mechanical workshops, warehouses, site offices, etc.
To establish detailed procedures for administration, supervision, and support activities.
To finalize the managing and supervising of the mobilization of the selected approved
subcontractors to site and to finalize the selecting and nominating of the materials and
equipment suppliers listed on the approved vendors list.
To manage and supervise the order and delivery of long-lead materials and equipment.
To manage and supervise the subcontractors to prepare requisition orders and purchase
orders for the job site facilities, construction equipment, small tools, consumable and
supplies, etc.
To get the approval of the Authority/Engineer for using the land where it is intended to
establish the temporary construction facilities.
Mobilization of personnel and equipment shall be carried out immediately and purchase contracts
with qualified manufacturers concerning plant and equipment to be purchased shall be signed.
Key temporary facilities including construction camp and auxiliary facilities shall be set up and early
preparation shall be completed in a shortest time to ensure the commencement of project as required.
Mobilization of Personnel and Equipment
Mobilization of key personnel to the job site will commence in accordance with the mobilization
schedule, together with the arrangements for the delivery of the major construction equipment and
tools required for the initial construction stage.
Mobilization of personnel is initially planned to be carried out in stages. At the initial stage, key
personnel shall be deployed according to the work schedule at site after the signing of the Contract.
And at the second stage, additional managers and staff shall arrive at site after the commencement
of the Contract depending on approved manpower schedule.
On the succeeding stage, deployment shall be in accordance with the work requirement. Most of the
construction equipment shall be company owned and some are to be purchased or rented locally.
Heavy equipment of appropriate capacity and number such as lifting cranes, bulldozers, hydraulic
excavators, wheel loaders and dump trucks are given priority for first mobilization on site.
The rest of the project resources, i.e., construction manpower, heavy equipment, plants, materials
and tools will also mobilize by the Contactor in accordance to the schedule work programme.

CONTRACT T316
Temporary Site Offices and Facilities
The Contractor will provide site office for the Engineer based on the requirements of the Contract in
Clause 5 of the Particular Specifications.
The site camp will consist mainly of main office building, car parking space and motorcycle lots,
portable site offices, dormitories, warehouses, workshops, facilities, etc.
Office furniture, telecommunication and I.T. systems and other facilities and office materials will be
provided as per the Contract requirement and technical specifications.
The Contractor’s main site office will be set up close to the Engineer’s site office to facilitate the fast
communication and coordination of works.
Figure 2: Work site and Access road Layout
Figure 1: Work Site and Access Road Layout

CONTRACT T316
Site Access
In general, the Contractor will utilize the existing road as access road connecting the site and the
office with the Authority’s approval unless otherwise necessary to provide for flexible/rigid pavement.
The access road will be constructed to the extent, lines, levels and standards indicated in the
specification requirements.????
Site Utilization Plan
Below figure shows the site utilization plan for the contract T316 work.
Figure 3: Site Utilization Plan Tentative Arrangement
Traffic Control
Information signboards will be placed at the advance warning zone to provide sufficient time for
motorists or road users to react to the lane closure. For the purpose of channelizing and delineation,
traffic cones will be placed on the road/access and supervisors will be present to ensure an orderly
and safe flow of traffic. Approved water-filled safety barriers will be placed at the work zone boundary
to prevent vehicles from entering the work area and minimizing injuries to passengers in the errant
vehicle.
During the works affecting the road, advance warning will be provided along the way to inform

CONTRACT T316
motorists of the impending lane closure. Similar advance warning signs will be placed during works
to other affected roads. For workers’ safety, proper access will be provided for workers entering or
leaving the work zone. High visibility safety apparel will be worn by workers at all times to improve
conspicuousness and increases safety at work especially for works at night.
Detailed Traffic Control Plan
A detailed traffic control plan will be submitted to the Authority and other local authorities’ approval
prior to carrying out the above works. Several key considerations are follows:
Several keys to consider for Traffic Control Plan
1. Work Duration 2. Work Location
3. Road Speed 4. Traffic Condition
5. Road Type 6. Type of Work
7. Road Location 8. Type of Operation
Based on the above considerations, a suitable design will be carried out for the Advance Warning
Zone, Transition Zone, Activity Zone and Termination Zone. The Contractor will hire traffic consultant
to develop a new traffic diversion scheme based on LTA’s notional traffic diversion scheme.
Implementation of Traffic Control Plan
A full-time qualified traffic supervisor will be appointed to implement the Traffic Control Plan. The
following stages will be carried out during the course of the implementation.
Preparation Phase
Verify approval of Traffic Control Plan
Prepare and obtain approval for method statement
Set out work zones by marking the position on the ground
Verify setting out is suitable
Determine and prepare all necessary traffic devices
Inform relevant authorities in advance of the day of implementation
Ensure all personnel involved are aware of their duties
Execution Phase
Ensure safe and orderly flow of traffic
Place traffic devices safely

CONTRACT T316
Check the adequacy of the traffic devices regularly and make adjustments if necessary
Ensure that all workers stay within the safe zone
Ensure access into and out of the work zone is safe and properly maintained
Ensure that any night lighting used does not affect road user’s visibility
Attend to any accidents or incidences on site immediately
Coordination with Relevant Authorities
Coordination with the relevant government authorities and agencies will also be a key aspect of the
planning and implementation of the works. The Contractor will have to coordinate to all relevant
agencies, owners and authorities that are believed to be affected prior to executing any work.
The agencies that are expected to be informed are listed below:
Relevant Agencies
1) Land Transport Authority
2) Traffic Police
3) Fire Safety Bureau
4) Public Transit Companies
5) Other Relevant Authorities

CONTRACT T316
Site Establishment
Pre-Condition and Post-Condition Surveys
The construction of Contract T316 which involves underground excavation of station and twin bored
tunneling may affect the adjacent buildings, utilities, and other properties, particularly during the
performance of deep excavation works and ERSS works, e.g., diaphragm wall and piling operations.
The trenching works of diaphragm wall, piling and the movement of heavy equipment may produce
excessive vibrations that can affect the adequacy and stability of existing structures nearby.
Moreover, the bored tunneling works may cause negative impact to the utilities that fall directly on
the track alignment and for foundations of the neighboring structure within the zone of influence.
To eliminate or minimize any claims of stakeholders arising out from such activities, pre-condition
and post-condition surveys, the Contractor will conduct on all structures and utilities adjacent to the
area of works. The Professional Engineer (PE) employed by the Contractor will carry out these
surveys. Project Team will confirm the extent of the survey area at the contract commencement stage.
Traffic Diversion
The Contractor will develop traffic management measures to facilitate activities such as land clearing
and tree felling, construction of temporary roads, traffic diversion around the worksites and setting
up of barriers along work areas and laydown areas before construction.
The notional temporary traffic diversion at North Finger is shown below and this will further develop
by the Contractor during the work process.
Figure 4: Notional Traffic Diversion at North Finger

CONTRACT T316
Utilities
The Contractor will determine all probable utilities installed or abandoned within the boundary of the
permanent work and will thorough check and identify those, which are available on site before project
commencement.
The Contractor will also confirm for existing locations of utilities being mentioned in the ITT, drawings
and specifications. Proper coordination to the concern Authorities in charge for these utilities will be
taken up accordingly and to ensure the protection of the installation and proper diversion and support
to all utilities related to works.
The Contractor will also facilitate proper coordination to appropriate authorities in charge to make
sure that all connections are made in place complying with all standard requirements for power and
water supply for office and project site use.
The Contractor will prepare a preliminary utilities subsidence report prepared by his own design
consultant. This studied report presents the expected total settlement, deformation and damages to
all utilities; and includes a programme for the monitoring of subsidence and measures proposed to
protect the utilities. The notional Diversion for utilities affected during construction are shown below.

CONTRACT T316
Figure 5: Temporary Control Cable Diversion Plan - Stage 1
Figure 6: Control Cable Reinstatement Plan - Stage 2

CONTRACT T316
Figure 8: Temporary Fire Hydrant Diversion Plan Stage - 1
Figure 9: Fire Hydrant Reinstatement Plan - Stage 2

CONTRACT T316
Figure 10: Temporary High Tension Diversion Plan Stage-1
Figure 11: High Tension Reinstatement Plan Stage - 2

CONTRACT T316
Figure 12: Temporary Sewer Diversion Plan Stage - 1
Figure 13 : Sewer Reinstatement Plan Stage - 2

CONTRACT T316
Trees Protection
Introduction
The Contractor will take care of the trees that are planted in the work site area and protection works
of trees must be accomplished before any site clearing activity occurs within 30 meters of retained
trees. No trees shall be felled, removed or trimmed without the prior approval of the National Parks
Board and only when directed by the Engineer. The following sections will describe the Contractor’s
proposal for protection of trees in detail. For the exact locations and details of trees, please refer to
the tree felling layout in the drawings provided by the Authority.
Objective
The objectivity of this Tree Protection Plan is as below:
● Confirm the trees on the site which are to be retained or removed during and after the
development.
● Confirm the limit of the Tree Protection Zone required for retained trees in accordance
to B.S. 5837.1991 guidelines and Particular Specification Appendix I - National Parks
Board (NPARKS’) Tree Protection Specification - Site Clearance.
● Propose an acceptable location for the installation of fencing for an effective Tree
Protection Zone.
● Propose proactive tree care measures which will be of benefit to the trees and help to
ensure their successful retention.
● To provide an appropriate procedure for the implementation of Tree Protection
Measures and synchronize the timing with Demolition and Construction activities.
● To secure the appointment of a designated International Society of Arboriculture ISA
certified arborist or NPark’s approved contractor on site to ensure that the Tree
Protection Zone is respected and that the protective fencing is regularly inspected and
maintained throughout the duration of the development.
Tree Survey
Staking out and Identification
Location of affected trees within the project site must be identified during construction.
Once the proposed construction layouts of the Contract T316 is finalized and approved by the
Engineer, the limits of all Tree Protection Zones shall also be staked in the field for NPark’s Prior
acceptance.
The tree or trees for retention shall be clearly marked on the accompanying approved project plan
with a solid green color line, blue or grey depending on their retention value.
They are often identified on site individually by a metal or plastic numbered tag attached to the trunk

CONTRACT T316
of the tree at between 1.5 – 2.0 meters above the ground level or where trees were inaccessible or
collectively recorded as groups, they are indicated as such on the plan for group identification.
Trees to be removed are to be clearly marked and identified on the accompanying approved drawing
in red with a dashed outline to differential it from the retained ones.
All tree identification and staking out of limits of all Tree Protection Zones works shall be performed
by the International Society of Arboriculture (ISA) certified arborist of the Contractor. The documents
for survey limits of all Tree Protection Zones in the site shall be submitted for Nparks’ prior
acceptance.
Work Method Outline
The Contractor shall demonstrate a genuine commitment to the successful retention of valuable trees
within the proposed location.
Any vegetation clearing required within the tree protection zone shall be accomplished with hand-
operated equipment. Appropriate protection zones for these trees should be determined.
Images of Affected Trees
List of Affected Trees (If have)

Tree Girth Height Species Tree Girth Height Species
No. (m) (m) No. (m) (m)
Trees to be removed shall be felled so as to fall away from tree protection zones and to avoid pulling
and breaking of roots of trees to be retained. If roots are entwined, the Contractor's appointed
International Society of Arboriculture (ISA) certified arborist may require first severing the major
woody root mass before extracting the trees. This may be accomplished by cutting through the roots

CONTRACT T316
by hand, with a vibrating knife, rock saw, and narrow trencher with sharp blades, or other approved
root-pruning equipment. The trees shall be cut near ground level and the stump ground out by an
ISA certified arborist or NParks' approved contractor.
The fencing or protection barrier specified to protect these trees should conform to B.S. 5837.1991
guidelines with NParks’ approval. The protection afforded by this method of fencing will help to
ensure that these trees will survive without detrimental effects during the construction.
Any unavoidable alterations required to the surface above the root zones within this distance (i.e.
within the fenced off area) should only be carried out after having first produced specific method
statements for these activities. All works within this zone should be carried out by hand, and under
the supervision of an ISA certified arborist or NPark’s approved contractor.
Protective fencing (stout) for Tree Protection Zones should be the first job undertaken on the site, in
advance of any clearing, demolition, excavation, construction of temporary office, storage, facilities
and other construction activities, including mobilization and storage of materials and equipment on
site.
Protective fencing must remain intact and in place and protection procedures must be adhered to
throughout the construction period. Removal of protective fencing should be the last job carried out
on the completion of the contract.
No mechanical traffic should be allowed above a tree’s root zone, since this could cause compaction
and damage roots of trees. If injury should occur to any tree during construction the Contractor's
appointed ISA certified arborist should evaluate it as soon as possible so that appropriate treatments
can be applied. No appropriate treatment shall be applied without the prior approval from NParks'.
The following activities should be undertaken by an International Society of Arboriculture (ISA)

certified arborist or NPark’s approved contractor:
● Review and ensure NParks' requirements with regards to work procedures, access
and haul routes, and tree protection measures are complied with at all times
● The Contractor's appointed International Society of Arboriculture (ISA) certified
arborist or National Parks Boards' approved contractor shall be permitted to remove
the tree in a manner that causes no damage to the trees and understory to remain
● Any damage to trees due to site clearing activities shall be reported to the NParks'
within 6 hours so that immediate approved remedial action can be taken to the affected
tree(s). Timeliness of the remedial action is critical to the tree's health
● All trees shall be irrigated at least three times per week for the period July -October
over the duration of the project. Irrigation must wet the soil within the tree protection
zone to a depth of 0. 75 meters
● No burnt piles or debris pits shall be placed within the tree protection zone. No ashes,
construction debris or rubbish may be dumped or buried within the tree protection zone

CONTRACT T316
● The stump and root of felled trees shall be grubbed up immediately and removed from
the site. All empty tree holes or cavities shall be filled with approved material to the
existing ground level and compacted to the satisfaction of the Engineer.
● Erection of protective fencing
● Briefing of site officials regarding procedures pertaining to trees.
● Any activity, planned or unforeseen, which may be required within the zone of
protection afforded by the protective fencing.
● Approval to remove protective fencing.
● Dismantling of protective fencing.
If unavoidable activities (such as demolition works) are required within the root zone of a tree, an
appropriate proposal shall be carried by an International Society of Arboriculture (ISA) certified
arborist or NPark’s approved contractor subject to approval of Npark prior to its implementation. All
protection works shall comply with the Npark Tree Protection Specifications (Particular specification
Appendix I-National Parks Board (NPARKS’) Tree Protection Specification- Site Clearance)
Protection Zone Calculation and Adjustments
During all operations within the tree protection zone, trees often become damaged or killed because
of injury they receive throughout the construction phase. This is usually due to root crushing injury,
root severance, mechanical injury from collision with above ground parts, soil compaction from
vehicular movements or soil contamination through spillage or tipping phototoxic material.
In order to prevent this from happening, a Tree Protection Zone (TPZ) is established for each tree
worthy of retention based on the requirements of each tree instructed by NPark. The amount of
protection required is evaluated and based on several factors. The Contractor's appointed ISA
certified arborist must monitor any grading, construction, demolition, or other work that is expected
to encounter tree roots.
The calculation of minimum distance of protection barrier or fence from the centre of the tree is based
on the three (3) items tree age, tree vigour and trunk diameter. Any identified tree subjects for
protection shall be verified on site by an International Society of Arboriculture (ISA) certified arborist
or NPark’s approved contractor to determine the actual trunk diameter, tree vigour and age. The ISA
certified arborist shall, after getting the actual values, compute the minimum distance of fence from
the centre of the tree. This calculation is a useful guide to ascertaining the appropriate location for
protective fencing intended to prevent disturbance and damage to trees during construction activities.
Overgrown tress may need to be prune for adjustment by cutting the overhanging branches and
foliage off to be totally inscribed in the fence. The computed minimum distance shall be submitted to
Nparks’ for reference and approval. Pruning shall be performed to American National Standards
lnstitute-A300, 'Pruning Standards' or International Society of Arboriculture "Tree Pruning Standards".
Some other factors are also considered when determining the appropriate size of the Protection

CONTRACT T316
Zones required for the successful retention of trees on a project site. For example, age class,
condition, species, site history, topography, location of former structures or services, etc. Also,
proposed new use and proposed new footprints for structures may be influential.
Protective Barrier or Fence
Once the TPZ is established, a ‘Protective Barrier’ is to be erected at the appropriate distances.
Protective hoarding with a minimum height of 1.8 m shall be erected as per the NParks' requirements
to protect trees to be retained. The hoarding shall define and demarcate a specific protection zone
for each tree or group of trees. Hoarding is to remain until all construction works have been completed
and only removed with the written approval of NParks.
Such fencing, if robust and fit for purpose, will offset injury or damage occurring to the critically
functioning of the retained tree during construction. When considering the activities of a construction
site it is necessary to use robust materials that can withstand the day to day working practices
through the duration of the development.
The barrier should consist of a scaffold framework comprising a vertical and horizontal framework,
well braced to resist impact, with vertical tubes spaced at a maximum interval of 3-metres. Onto this,
weld mesh panels should be securely fixed with wire or scaffold clamps. This type of fencing is
preferred because it is readily available, resistant to impact, can be re-used and enables unhindered
inspections of the protected area.
(Weldmesh panels on rubber or concrete feet are not resistant to impact and must not be used).
Plywood or approved equivalent may be utilized as walls of fence in lieu of weld mesh in some
locations that need blinds for the passing public.
Site Hoarding and Access Control
The Contractor will provide and erect all necessary protective screens, hoarding and the likes that
may require to prevent damage, nuisance or disturbance to adjoining properties, roadways, persons
or traffic passing nearby prior to the commencement of the work under the approval and acceptance
of the Engineer.
Unless otherwise stated in the specification, the Contractor will erect the hoarding as indicated on
the drawings following the requirements of the specifications.
The Contractor will post sufficient warning signs at conspicuous locations on the hoarding to alert
the public when the work is in progress. Proper attention will be given to sufficient lightings during
the night to properly mark out all entry and exit points on hoardings for heavy machineries and
vehicles leaving and entering the site.
The Contractor will construct gates, barriers and other security structures for the regulation of
incoming / ingress and outgoing/egress of vehicles or equipment on site, hire Security guards for the

CONTRACT T316
regulation and control of the entrance, and exit points during working and non-working days.
Site Setting Out
The Contractor will employ competent resident surveyor approved by the Engineer that will head the
Contractor’s survey team for all site survey and setting out works. The Authority has designed and
issued the alignment plan.
The Engineer shall issue to the Contractor a set of Primary Survey Control Markers as the source to
establish the horizontal and vertical control of the Works at the award of Contract.
The Contractor’s resident surveyor will check the actual co-ordinates and levels of the handed over
Primary Survey Control Markers against the Authorities provided co-ordinates and levels based on
the adopted co-ordinates system and will quickly notify the Engineer if found any discrepancy.
The Contractor will take the responsibility to protect and preserve the integrity of the Primary Survey
Control Markers and will provide protection steel rails after handed over by the Authority.
Unauthorized people will not be allowed to enter the premises save the Survey Team of the
Contractor and the Engineer. The Contractor’s survey team will establish Secondary Survey Control
Markers at appropriate locations around the site reckoned from the supplied Primary Survey Control
Markers.
These Secondary Control Markers will be propagated around the Project site to act as survey controls
for all work areas. It will also be marked for easy identification and physically protected from damage
and be available for Engineer’s verification.
The Contractor’s survey team will carry out Pre-computation prior to establishment of any setting-out
points on site. All pre-computation of orientation, e.g., Northings, Easting, Elevations, Azimuth, Back-
sights, Fore-sights, etc. of all setting-out points will be readily available in a spreadsheet format and
be submitted to Engineer for approval prior to on-site staking out.
The survey accuracy of the marks will commensurate with the requirements in the Tender documents.
The Contractor will use Total Station survey instrument in all site surveys and will hire the services
of a local Registered Surveyor for setting-out involving property boundaries.
In the setting out process, all elevation conducted by levelling will start on an established survey
control markers and finish on a different survey control marker. The survey team will take necessary
corrective action after detecting significant differential elevation error after the survey.
The Contractor’s survey team will transfer all the alignment on the ground and identify all the
encumbrances, which may come in the way of construction and advice to the Authority who will take
the necessary action for removal of the same.
It is presumed that the Authority has taken action to acquire requisite land or has the permission of

CONTRACT T316
the state authorities for construction of the Project in the proposed alignment.
If any portion of the Project passes through any private land for which land acquisition has not been
done, the same would be advised to the Authority for taking appropriate action to acquire the same,
to avoid delay and allow continuous sequential working with minimum shifting of resources.
The Contractor’s survey team will also undertake the topographic survey of the work areas to verify
the accuracy given data in the drawings and to establish the actual ground features as reference for
any volume computations for earthworks. The survey report is submitted to Engineer for acceptance.

CONTRACT T316
Ground Improvement
General
The Contractor will use grouting to solve variety of geotechnical issues during constructions. Grouting
is a process of injecting a cementitious compound or mixture into the ground to improve condition by
strengthening or stiffening of soil or fractured rock, sealing of gaps in rock and increasing
impermeability or imperviousness of soil or rock. Grouting technique can cutoff groundwater,
strengthen soft in-situ soils for tunneling support and remediate ground settlement caused by
excavation. Rows of holes are bored in the soil and usually cement grout, are injected under high
pressure. The cement grout will penetrate into the voids of the sub-soil and form an impermeable
vertical curtain separating the ground water and act as a support for weak soil. Grouting is also used
for consolidation of weak soil or rock to form into hardcore or solid mass when the consolidating grout
hardened.
Jet grouting will be mainly used to improve the soil condition base on the given data information for
Contract T316. The jet grouting is proposed as ground improvement for clay below the bored tunnel
at both ends. Other grouting method will be taken into consideration if it is required and approved by
the Engineer. The Contractor will take extra measures to make sure that any grouting works will not
pollute the water near the work area.
Although, jet grouting is the preferred method for ground improvement as of this stage, other grouting
methods are also discussed for information. The Contractor’s PE (Geo) will propose and submit
design and details of ground improvement methods to the Engineer, QP(S) and to other relevant
authorities.
This proposal is for the acceptance of the impact assessment of the proposed methods and to
demonstrate that there is no adverse impact to the adjacent ground, structures and utilities.
Ground improvement of any kinds and other methods of minimizing groundwater drawdown
(including recharge wells) are considered a part of the Contractor's method of tunneling.
Groundwater drawdown shall be kept to a minimum. The Contractor shall identify locations where
ground improvement is required to facilitate the construction Works. The ground improvement maybe
classified as Temporary Ground Improvement (as for the tunnel machine breakthrough) or
Permanent Ground Improvement (stabilization of weak soils, waterproofing or drainage of land to
accelerate its settlement).

CONTRACT T316
Ground Improvement Location
The ground improvement locations are shown in the following sections of this method statement:
For at-Grade/underground structures - Section 7.6 Ground Improvement (Station)???
For Bored Tunnel - Section 8.6 Ground Improvement (Tunnel Alignment)???

CONTRACT T316
Improvement at Different Types of Ground
The figure shows the Ground Improvement to apply for areas with different Soil and Rock Type
N1 A. Jet Grouting Pile
N5
N10 N<35
JET GROUTING PILE
N15
N20
N25
N30
N35
N40 B. TAM Grouting
N45
N>35
N50 TAM GROUTING
SPT VALUE
N55
N60
N65
N70
N75
N80
N85
N90
N95
N100
N105 C. Fissure Grouting
N110 Grouting within a rock mass

(not applicable for Contract T305)
Figure 14: Ground Improvement at Different Soil and Rock Types

CONTRACT T316
Jet Grouting
General
The Contractor is proposing to apply the jet grouting method for the soil or ground improvement for
project work.
Jet grouting is a grouting technique that creates in situ geometries of soilcrete (grouted soil), using a
grouting monitor attached to the end of a drill stem. The jets erode and mix the in situ soil as the drill
stem and jet grout monitor are rotated and raised.
Depending on the application and soils to be treated, one of three variations is used:
the single fluid system (slurry grout jet),
the double fluid system (slurry grout jet surrounded by an air jet) and
the triple fluid system (water jet surrounded by an air jet, with a lower grout jet).
The jet grouting process constructs soilcrete panels, full columns or anything in between (partial
columns) with designed strength and permeability. Jet grouting has been used to underpin existing
foundations, construct excavation support walls, and construct slabs to seal the bottom of planned
excavations.
Jet grouting is effective across the widest range of soil types of any grouting system, including silts
and most clay. Because it is an erosion-based system, soil erodibility plays a major role in predicting
geometry, quality and production. Cohesionless soils are typically more erodible by jet grouting than
cohesive soils. Since the geometry and physical properties of the soilcrete are engineered, the
properties of the soilcrete are readily and accurately predictable. In any situation requiring control of
groundwater or excavation of unstable soil (water-bearing or otherwise) jet grouting should be
considered.
Usually, jet grouting can be accomplished without disrupting normal facility operations. The recent
development of small containerized, highly mobile support equipment has enabled to start jet
grouting work on the first day of setup, greatly reducing mobilization and demobilization costs. Jet
grouting can often result in construction schedule savings.
Procedure
Technique of Ground Improvement Works as follows will be proposed to enhance the ground stability
some location identified for Bored Tunnel alignment. Jet grouting employs cement mixing technique
in which cement acts as binding agent to mix with the existing soil to achieve better strength and
deformation properties. The principle of this technique is based on pozzolan by the cement hydration
to create a compound, which will strengthen the ground.

CONTRACT T316
ADD CEMENT ADD WATER
Poor Soil
Condition
Mix & Agitation
Early Hardening Hydration Pozzolan Hydration
Lime is strongly combined

Hardened from colloid to w/ clay - Lime Chemical
crystallized condition Hydration Reaction
Condition
Enhance
Soil
Condition
Figure 15: Jet Grouting Schematic Diagram
The Hydration process occurs during the mixing. For JET GROUTING, the mixing is carried out by
the compressed air.
It is constructed by employing high pressure fluids that are injected into the designated soil strata at
high velocities. In this project high energy jet water will be used to break soil around the drill string.
The passage of the jet of water through the soil is aided by an aureole of compressed air concentric
about the jet.
The compresses air increases the radius of influence of the jet of water and it “lightens” the mixture
of soil and water in the zone of influence of the jet, creating an air-lift that pumps excess water and
soil fines, through the annular space between the borehole wall and the drill rods to the surface.
At the same time, cement grout is injected into the soil and mix with the soil by employing a high
pressure pump. In time, the cement grout and the soil set to create a column of stabilized material of
diameter depending on the pressure of the compressed air.

CONTRACT T316
It shall be employed for JET GROUTING works to achieve the following requirements:
Description Requirements
1) Minimum Unconfined Compressive 800 kPa
2) Strength
Modulus of elasticity (Eu) 180 MPa
3) Undrained Shear Strength (Cu) 400 kPa
4) No. of Coefficient of Permeability More than 1 x 10-8 m/s
5) Total Coring Recovery (TCR) Not less than 85%
Reference Code of Practice
All of the works shall comply with the relevant requirement of the Standard and Codes listed below:
Singapore Standards
SS CP 79: Safety Management system for Construction Worksites
British Standard:
BS EN 12716:
● Execution of Special Geotechnical Works – Jet Grouting

BS 5930: 1999 :
● Code of Practice for Site Investigation

BS 5228:
● Noise & Vibration Control on Construction and Open Sites (Part 1)

● Code of practice for Basic Information and Procedure for Noises and Vibration Control
● Noise and Vibration Control on Construction and Open Sites (Part 4)
● Code of Practice for Noise references shall be used for guidance in carrying out the
works
The following technical references shall be used for guidance in carrying out he works:
● API-RP-13B-1: Standard procedure for field-testing water based drilling fluid

● eNPQS : Specification of C2-40 on Jet Grouting
In case any circumstances indicate different conditions from those expected or require special
procedures for the execution of the works such circumstances will be reported to the Engineer.

CONTRACT T316
Construction Sequence
In Jet grouting, a double tube jet grouting system consists of three concentric hollow stem pipes, the
iner one carrying grout, the intermediate pipe carrying water and the outer pipe supplying air, is used.
Jet grouting shall first be constructed at the inclinometer’s location to ensure that the pressure of the
water and air would not cause the deflection of the surrounding area fo the structures in the vicinity
to exceed the allowable limit as stipulated in the Specifications.
Figure 16: Jet Grouting Work Sequence

Preparation works
Choose the desirable final strength on the treated soil to determine the amount of cement
that should be injected into each cubic meter of treated soil.
Choose the column diameter of the soil to be treated and calculate the amount of cement
that should be injected per meter of column
Choose the composition of the water-cement mix ratio. In a water-cement mixture, the
proportion of water and cement will affect both its pup ability andits strength. The higher the
water cement ratio, the higher the pump ability of the mix, but lowers its final strength.
Determine the required pressrue to construct the underground column of specific diameter.
Perform underground survey prior to work commencement.
Survey the location of the column.
Prepare the cement grout based on the proposed water-cement ratio and mix.
Prepare shop drawings of ground improvement monitoring points for all locations.
Setting-up Equipment and Machinery for Jet grouting

CONTRACT T316
Assemble the drilling machine on site
Attach the drilling machine with necessary mixing equipment (such as auger, rod) for jet
grouting.
Set up the cement silo and the mixing plant
Surveying the location of Jet grouting
Peg the location of the jet grouting as shoen in the approve shop drawings by the land
surveyor
Resurvey and repeg the position in the event that the initial peg is displace or lost.
Check the position of the peg by putting distant reference points to ensure its accuracy.
Base line ground movement monitoring points
Figure 17: Marking of Jet Grouting Location through Survey
Positioning of Jet grouting machine
Level the platform for the drilling macine by placing steel plates
Position the drilling machine at the pegged location of the Jet grouting.
Check the verticality of the drilling machine using the sprint ruler that is attached to the
drilling machine and the plumb-lines method from two perpendicular directions.
Confirm that the verticality of the Jet grouting shall be performed by the machine operator
and the site supervisor
Commencing Drilling works for Jet grouting

CONTRACT T316
Permit to work (PTW)
Check the nozzle that is used to inject the cement grout by visual inspection priorto the
drilling works. A simple water test shall be conducted if necessary. The water test tuilizes
the injection of water into the rod tubes. If the water successfully emits from the nozzle, the
nozzle is in good working condition.
Check the pressure of the pump by visual inspection of the dial pressure gauge
Execute drilling of a small diameter borehole to the designated depth using low pressure
water flushing from the bottom for the jet grouting works.
Measures and record the designated depth manually from the balance rod above the
ground level and compared with the actual length of the rod on the check sheet
Remove the slime from the designated depth
Inspect the slime to ensure thatit corresponds with the soil condition ( given by the Authority)
Constructing Jet grouting
Inject water with water-cutting pressure of approximately 150~250 kg/cm2 and air with a
pressure of 8 ± 1.5 bars to break up the soil surrounding the drill string once the drilling
works reached the required depth of the jet-grouting (390 ± 10 bars) works.
Control the pressure of the compressed air by the dial pressure gauge
Displace the finer particles of soil by airlift as the drill string is roitated, and from the diameter
of the borehole.
Inject cement grout with high pressure pump through the nozzle screen when the drill rod
is slowly withdrawn from the borehole. The injection rate of the cement grout will be 449
liters per meter
The withdrawal rate will be decided base on the mixing design
The removal or uplifting by rotation of the drill rod is carried out at a rate of 5~8 rpm to make
underground column.
Measure and record the cut-off level of the jet grouting manually from the balance of the rod
above the ground level and compared with the actual length of the rod.

CONTRACT T316
Figure 18: Jet Grouting Work Flow Chart
Quality Assurance
Quality Control System
Checkpoints
● Check verticlaity upon equipment set-up

● Check soil condition and slime/slurry colume to comply with the designed condition
● Meet with the most reasonable mixing ratio
● Control the Jet grouting pressure and cement grout volume by intimate coordination
with drilling machine and high pressure pump
● Control the cycle time between precedent anf post work.
Check List
 Grout Batching
 Pump pressure
 Compressed Air pressure
 Jet Grouting Pile Cut-Off level and Toe Level
 Stoppage in Jet grouting
 Accuracy of jet grouting positioning

CONTRACT T316
Quality Safety Method
Monitoring and controlling of ground movement, buildings and utilities within the influence zone
of grouting during jet grouting drilling and grouting procedure.
● To do pre-cutting at two (2) to three (3) times

● To decrease the pressure of the hydraulic pump
● To set control points for monitoring before and after jet grouting works
● Installation of release pipes to release the jet grouting pressure at the service areas.
Monitoring
A grid of settlement/heaves monitoring points over the area at spacing of not greater than 5m is
established.
All buildings, structure and utilities with a distance of 1.5 times the maximum depth fo grouting
for movement are monitored.
All point at least twice per day when drilling/grouting work is in progress, are monitored.
Proposed Jet Grouting
Cement content to be used for Jet grouting should be 480 kg/m3 (OPC). Please refer to Table below
for Jet Grouting Corresponding Parameters.
Construction sequence for Jet Grouting
Drilling rig shall be set up in position
Drill to the required toe-level, water shall be used/ applied, rotary wash drilling during drilling
stage.
Drilling rods to toe level and jet grouting is then commenced by withdrawing and rotating
the rods at pre-determined rates.
Upon completion, the rods are completely withdrawn and cleaned. The ris is then moved to
the next location.
Any adjacent points will only be installed minimum 12 hours after installation of the current
point.
Operating Parameters
The parameters for the Grout Pile corresponding parameters shall be in the range as follows:

CONTRACT T316
Table 1 Jet Grouting Operating Parameters
Parameter 1.0 m Diamater

Grout flow rate 130 ± Liter/min
Grouting pressure at pump 390 ± 10 bars
Air pressure 8 ± 1.5 bars
Withdrawal rate 3.3 min/m
Rod rotational speed 5 ~ 8 rpm
Grout water / Cement ratio 1:1
Design Strength / Stiffness
Table 2: Design Strength/ Stiffness

Description Unit Requirement
UCS kPa 800
Cu kPa 200
Eu MPa 180
TCR % 85
Permeability m/s 10-7
Coring Test
The Qualified Testing Company (IDT) will conduct the coring test
The Qualified Person (QP) will choose the Jet Grouting points.
The coring pionts to be at the overlapping area of the pile
The quality of jet grouting shall be confirmed by SPT and Coring Test
Quality Control
Setting-out
Electronic Total Station (Data Logger) will be used in setting-out each Jet Grouting point location.
Parameters and Frequency fo Checking
Parameter Checked Method Frequency Document
JG Plant Daily
Grout Mix Density Mud Balance Min. Twice Daily
Checklist
Pump Motor RPM/ JG Plant Daily
Grout Flow Rate Min. Twice Daily
Data Logger Checklist
Grouting Pump Pressure Gauges. Min. Twice Daily JG Plant Daily

CONTRACT T316
Pressure Data Logger Checklist

Verticality/Inclination Spirit Level Every Jet Grouting JG Column Report
Stop Watch/ Data
Withdrawal Rate Every Jet Grouting JG Column Report
Logger
Stop Watch/ Data
Rod Rotation Every Jet Grouting JG Column Report
Logger
Pressure Gauge at
Air Pressure Air Pressure/ data Every Jet Grouting JG Column Report
Logger
Level of Jet Grout Leveling Instrument/
Every Jet Grouting JG Column Report
Column Data Logger
Specific Gravity and Mud balance, Marsh
One per Pile JG Column Report
Viscosity Cone
Data Logger system sample
Figure 19: Data Logger System

CONTRACT T316
Figure 20: Data Logger Data Sheet
Jet Grouting Plant Layout (Indicative)
Figure 21: Jet Grouting Pile Plant Layout

CONTRACT T316
Proposed Equipment and Anticipated Cycle Time
Table below shows the output capacity of the proposed equipment proving their suitability and
reliability for the work.
Estimated
Quantity
Item Equipment Description Output Remark
(Capacity)
per Day
High Pressure 1
1 For injecting cement grout
Pump (400 bar)
For drilling works for soil 1

2 Hydraulic Drilling
treatment (EMB 1-103)
For storing cement 1

3 Silo
powder (50 ton)
1
4 Generator For power supply
(300 kW )
1
5 Air/ Comp. Air supply for drilling
(10 bar)
For mixnig cement & 1 100
6 Mixer Plant
water (500~600L) m3/day
1
7 Water Tank Pre-cutting, Grout Cement
(15 m3)
High Pressure Connection pump to rig 500m
8
Hose for cement grout injection (1 inch)
1
9 Hydraulic Hose 400 bar
(3/4 dia.)
For level the area & slurry 1
10 Excavator
removal (0.7 m3)
Monitoring 2
11 Measurement
System (Data Log)

CONTRACT T316
Other Types of Grouting
General
Aside from Jet grouting, other types of grouting techniques are available that can be used if required
and approved by the Authority. Other type of grouting is explained below succeeding section.
Tube A Manchette (TAM) Grouting
TAM grouting method which uses Tube-A-Manchette pipe and

double-packer is carried out by combining controlled
compensation grouting and permeation grouting. TAM pipe is
usually perforated at intervals of 30~50 cm and is used with
an inner grouting pipe containing two packer elements. It is
installed in the ground will allow grouting to be carried out
individually and repeatedly.
It provides precise control and flexibility which are needed in

the process of controlling settlement of buildings, roads and
tunnels. The tube is a PVC or metal pipe in which rubber
sleeves cover holes that are drilled in the pipe at specific
intervals.
The tubes are inserted into holes that have been bored into
the "work area" known as the "grout zone". Grout is pumped
to a packer that has been slid into the tube. Seals on the
packer force the grout through the holes in the tube, past the
flexible rubber sleeve, and into the grout zone to help stabilize Figure 22: Typical TAM Grouting Section
and/or seal it.

CONTRACT T316
Underground Infrastructure Building
General
The Contractor will briefly describe the method to execute the proposed Underground Infrastructure
Building in this document and will be subject for review and comments by the Project Manager
subsequent to contract award. The project team will further develop a detailed method statement
prior to commencement of works. The construction methods explained in this document are for
tender stages only and amendment will be made after award of contract. Actual geological and
geotechnical conditions encountered on site during the progress of works may likewise act as
catalyst for changes and revision of this method statement to suit the actual site conditions and
requirements.
Construction Sequence Diagram of Underground Infrastructure Building
Perimeter
Architectural
Layout Ground
Work with
& Improvement
M&E
Hoarding
ERSS
Site
Site Clearing D-wall, &
Reinstatement
Barrette wall
Excavation
Recharge Well Work
(Bottom Up)
Construct wall
Pile Works &
Slab concrete
Floor by floor

CONTRACT T316
Construction of Underground Infrastructure Building
Refer to MS for Construction of Underground Infrastructure Building Document.
Stage 00
● Site Mobilization, precondition survey of existing condition of site

● Preparation for site access, site office, equipment and materials storage arena
● Demolition of Katong Park Child Learning Center
Stage 1A
● Carry out traffic diversion stage 1A
● Erect sound barrier and fences stage 1A

● Install guide wall, D-wall, soldier pile with sheet pile lagging, cross wall, bored piles
and king post to work area to the desired depth
● Cast Roof slab
● Backfill to ground level

CONTRACT T316

CONTRACT T316
Protection and Diversion of Existing Utilities
Affected Utilities
Affected utilities have been identified based on the station layouts. At present major utilities affected
by the proposed station location are:
Gas Pipelines
Low Voltage(LV) & High Voltage (HV) Cables
Telecommunication Cables
Water Pipes
Sewer pipes
Method to Protect Utility Services
The Contractor will divert or abandoned all public utilities that pass through the station area will be
diverted or abandoned accordingly following requirement.
Appointment of a dedicated Utilities Engineer, who shall be solely responsible for all utilities
matters. He has previous experience in managing utilities-related matters and his
fundamental role will be to ensure no utility damage occurs.
Conducting co-ordination meetings with all of the relevant utility service agencies and
obtaining latest information before construction works commence.
Carrying out a detailed study of the utility drawings and correlating with both the Temporary
and Permanent Works to determine the affected services.
Appointment of a Licensed Cable Detection Worker (LCDW) to scan the work area and
identify all known and unknown services. Prior to the commencement of cable detection
work on Site, the Contractor shall verify that the cable detection instruments are calibrated
to manufacturer's standard requirements and in good working condition until completion of
the cable detection works.
The work area must also be scanned for gas and water and any other utilities. Arrangements
must be made to 'charge' cables if necessary to facilitate their detection. In particular this is
likely to be necessary for the detection of cables to street-lights, ERP and traffic lights.
Appointment of a specialist trial trenching team to find all identified services. Only manual
excavation will be allowed, with standing supervision by the Contractor's Site Supervisor.
Producing detailed plans and sections identifying utilities and installing ground markers and
identification signs at the location of services.
Implementing a "Permit to Dig" (PTD) system which is a mandatory for any excavation or

CONTRACT T316
digging activities. The permit shall incorporate all the services identified during the cable
detection process and must be authorized by the Contractor's Utilities Engineer and the
Engineer.
Only when the PTD has been duly signed by the Authorized Persons, can manual
excavation, in incremental layers, be carried out to locate the services. The Contractor's
Site Supervisor shall oversee the excavation works.
Wherever services are discovered, the relevant utility agency is called in to verify the
exposed utility on site. Wherever services are said by the Utility Agency to be abandoned,
these must be proved to be dead by drilling of the pipe or spiking of the cable in the presence
of the Agency. The Contractor shall not on his own initiative remove or throw away any
identification markers or cable slabs, or attempt to lift up or divert the cables.
The utilities shall then be protected or supported in the manner approved. If the trial trench
is to be backfilled, the extent of utilities must be clearly identified by posts or pipes either
concreted or driven below the level of the services, such that they would not be disturbed
by subsequent excavation. Pegs that can be easily disturbed and replaced would not be
acceptable.
Heavy construction vehicles such as cranes and piling rigs shall not be allowed to cross or
pass within 1.5m of these utilities without prior protection.
During the course of the construction works, no mechanical excavation shall be allowed to
proceed until each and every known utility in the area has been exposed manually. If a
known utility cannot be located, the work must stop until further cable detection, or site co-
ordination with the concerned.
Agency, has identified its location away from the area. Earthworks, using mechanical
excavators can proceed only upon certification by the Licensed Cable Detection Worker
that the area to be excavated is free from electricity cables as well as from other Utility
Services verified by the Contractor.
Personnel found to be negligent in following the above shall be removed from the site.

CONTRACT T316
Utilities Support
Any sewer pipe that cannot be avoided to cross the station will be hung underneath the traffic decking
during traffic diversion as follows:
Water main support Drain diversion
Sewer pipe support Utility pipe hanging

CONTRACT T316
Sample Picture of Steel Grid
Utility Diversion ???
Site Clearing???
Trees and Abandoned Utilities
Prior to commencement of the Works, the Contractor’s will employ Arborist that will submit the
prepared actual survey of trees, bushes, hedges, etc. to the Engineer based on actual site condition
affected by the proposed Works of the Contractor compared to the tree felling plan approved by
NParks provided by the Authority in the Tender document.
Any discrepancy will need approval from Engineer and Nparks before the felling of trees is carried
out by the Contractor.
Trees indicated in the Authority Drawing marked as to be retained and transplanted will be subject
for tree protection program by the Contractor being coordinated to the NParks. Further details, refer
to Proposal Protection of Trees_T316 document.

CONTRACT T316
Ground Water Control
Deep excavation dewatering is often a significant source of settlement, noted that excavation
dewatering can cause consolidation of soil and leads to ground settlement in the affected area.
Dewatering can cause settlements over a much larger area than the area affected by the excavation
itself. Dewatering can also cause ground loss in fine sands or silty soils.
Therefore, the Contractor will use the control of groundwater in order to ensure stability of excavation
and limit groundwater drawdown resulting from seepage into excavations. The Contractor will install
ground water control system beneath the excavation bottom subject to the acceptance of the
Engineer and QP(S).
Ground water control system, including recharge wells, will control the groundwater drawdown to
prevent possible hydraulic uplift.
The Contractor will install Recharge wells in the station construction area as per the notional drawings
provided by the LTA. The following figure shows the recharge wells and ground water lay out plan.
Typical Recharge Well
As prerequisite and prior to the undertakings of excavation works, the Contractor will install and
commission the engineered recharge well system designed and endorsed by his PE to control the
groundwater drawdown and to control the hydraulic lift respectively.
The engineered dewatering system for excavation works designed and endorsed by PE will also be
installed and commission for control the groundwater in the excavation.
Table 3: Construction Details for Type Marine Clay
Ø Borehole : 200mm
Ø Screens and Casting : 80mm above top of Marine Clay
Length of Plan Casting : Minimum 5m Below Station / Tunnel Formation Level
: For screens > 4.0m long, two or more screen each 2.0m
long maybe used separated by lengths of plan well casing
≤ 2.0m long
Perforated Pipe: Size/Open Area : Min.50 Dia. uPVC Perforated Riser Pipe 6% Open area
formed by 5mm Holes
: Wrapped in 2 Layers of Nylon Mesh (2mm Openings)
Gravel Pack : Clean 10mm Gravel Filter
Type Bentonite Seal (Slurry Mix) Ratio

CONTRACT T316
Bentonite: Portland cement: Water 0.3: 1: 4.5
Table below shows the output capacity of the proposed equipment proving their suitability and
reliability for the work.
Estimated
Quantity
(Capacity)
per Day
Drilling rigs 1
1 C6 Drilling Operation
(97psi) 5
Air 1 Nos. /day
2 Air supply for drilling
compressor (10 bar)
Ground Improvement (Station)
The Contractor will undertake the necessary ground improvement at the Underground Infrastructure
Building area indicated on the drawing prior to any ERSS installation and the subsequent excavation.
The Contractor’s PE (Geo) will propose and submit design and details of ground improvement
methods to the Engineer, QP(S) and other relevant authorities for acceptance for the assessment of
the impact of the proposed methods on adjacent ground, buildings, structures and utilities, and to
demonstrate that there is no adverse impact.
The Contractor may carry out soil investigation to confirm which type of ground improvement is
required in each location and submit proposal for approval by Engineer.
The Contractor will carry out ground improvement works with adequate instrumentation and
monitoring (IM) works designed and endorsed by PE for acceptance of the Engineer.
Further details for ground improvement; refer to MS for Ground Improvement_T316.
Diaphragm Walls and Barrette
General
Diaphragm walls and barrette walls are underground structural elements which are used for retention
system and permanent walls. These are also used as deep groundwater barriers.
These underground structures are constructed using the slurry trench technique which involves
excavating a narrow trench that is kept full with engineered fluid and slurry. The slurry exerts
hydraulic pressure against the trench walls and acts as shoring to prevent collapse. Slurry trench
excavations can be constructed in all types of soil, even below the ground water table.
This method involves injecting stabilizing agent at low pressure into soft ground (cohesive soil, sandy
soil, organic soil) or ground with high permeability (sand and gravel layer, completely weathered soil)

CONTRACT T316
and mixing by stirring using a special agitator.
It is a highly reliable method that minimizes pollution such as noise, vibration, and disturbance of
adjacent ground.
These retaining structures find following applications: earth retention walls for deep excavations;
basements, and tunnels; High capacity vertical foundation elements; Retaining wall foundations;
water control.
In general, diaphragm walls and barrettes will be excavated by grab cutter or by means of hydro-
fraise.
Bored Piles at the Proposed Station and Entrances
After the preparation works, i.e., site clearing, ground improvement, recharge wells and leveling of
foundation area to formation level, the Contractor will commence the installation of bored piles. The
depth and diameters of the piles vary according to the drawings and geological report provided. The
Contractor will install and cast concrete of bored piles as per the approved drawings and following
the requirements of technical specifications.
Details for Bored pile work; refer to MS for Construction of Bored Piles_T316

CONTRACT T316
Excavation Method for Station
General
The Contractor will use two kinds of excavation procedure for construction of Katong Park Station
i.e., the top-down and bottom-up methods.
Generally, top-down excavation procedure will be utilized for the construction of whole Katok Park
Station except only at entrances where the bottom-up excavation method is recommended.
The general sequence of excavation work will follow the sequence of road diversion traffic work.
The excavation will use the engineered ERSS wall consisting of diaphragm walls, struts and wales
for support and stabilization of vertical faces of excavation.
Associated works like dewatering system and recharge wells system will also be installed as
groundwater control system.
Ground improvement works under the ambit of scope will also be carried out as scheduled including
installation of kingposts/temporary bored piles and wales and struts as indicated on the drawings.
Before any earthwork commences, the Contractor will seek written permission from PUB and other
relevant Authorities.
Excavation Procedure
Top-down Method
As a prerequisite and prior to the undertakings of deep excavation works, the Contractor will install
and commission the engineered recharge well system designed and endorsed by his PE to prevent
the groundwater drawdown as indicated on the drawings.
The engineered dewatering system for excavation works designed and endorsed by PE will also be
installed and commission for control the groundwater during excavation.
Once the ERSS walls (D-wall), bored/barrette piles and temporary kingposts have been installed in
place and the ground improvement has been done, the excavation will commence. The excavation
will continue until 1.0 m below the strut S1.
The wales and struts for S1 will be installed accordingly and then the excavation will proceed up to
the bottom of blinding concrete of roof slab.
The ground formation for roof slab will be leveled and compacted then blinding concrete will be cast
and followed by the casting of roof slab concrete.
Temporary openings on roof slab will be provided as indicated on the drawings for enabling the works
under the roof slab.
TENDER DOCUMENT Page 58 of 225

CONTRACT T316
These roof openings will serve as ingress and egress of excavated materials and other construction
resources, i.e., manpower, materials and equipment for the remaining works under the roof slab.
After the roof slab has been cured to required strength and firmly jointed to D-wall, then the temporary
strut S1 will be removed and then waterproofing, backfilling and compaction works will proceed on
the top of the roof slab up to the road level to enable the restoration works and diversion of the road.
The excavation work for the concourse slab below the roof slab will commence up to the bottom level
of the concourse slab and casting of concrete will follow.
All excavated materials will be brought up through the slab openings. The work procedure will be
repeated until the bottom floors and all associated works are completed.
Once the openings on the floors become redundant or not anymore needed in the works, it will be
closed and all associated works will be carried out and completed.
Excavation and Muck Removal Arrangement
Excavation from existing ground level down to the bottom of roof slab
The Contractor will carry out the surface excavation using standard arm excavators. The
excavation will start at the middle moving toward the sides. The temporary wales and struts for
S1 will be installed once the excavation level is 1.0m below the center of S1.
After the installation of strut S1, the excavation will continue to 100mm below the soffit of roof
slab. Smaller size excavators will be brought down to excavation pit, if necessary, to help the
excavation works.
The excavated soil will be directly loaded to dump trucks to haul the materials into approved
disposal areas.
Excavation from roof slab level down to concourse slab level
The Contractor will carry out the excavation for concourse level using smaller size excavators,
smaller dumpers and telescopic dipper.
The smaller size excavators and smaller size dump trucks will be brought down to concourse
slab level through the roof openings by crane to carry out the excavation works for concourse
slab.
The smaller size excavators will carry out the excavation and load the excavated materials to
smaller size dump trucks to haul and tip off the excavated materials under the slab openings.
Telescopic dippers on the ground/roof level beside the slab openings will scope and lift the
stocked excavated materials at the concourse level up by its grab bucket through the slab
openings and load into dump trucks at the ground/roof level to haul and dispose the loads to

CONTRACT T316
approved dumping areas.
The Contractor’s excavation crew will, during the excavation of soil, take precautionary measure
for excavating the top soil near the roof slab as the blinding concrete under the roof slab may
splinter off or fall down during excavation.
All excavation crew will be alerted on this matter to avoid any untoward incident that it may
cause if taken for granted. All blinding concrete under the roof slab will be removed with great
caution.
If hard rock is encountered, vibrating hammer will be attached to the small excavator for hacking
off the rock or pneumatic hand jack hammers will be used by labors to break the rock into bits.
Pneumatic drill machines will also use to drill holes in the rocks to assist in the breaking of the
hard rocks.
The Contractor will also use a less sound, less vibration and less pollution methods of breaking
rocks by rock splitting using hydraulic splitter and by chemical blasting.
If water is present, sump pits with drainages will be provided to collect the water and dewatered
by submersible pumps with attached flexible rubber hoses for diverting water out of the
excavation.
The excavation will continue to 75 mm below the concourse slab level for blinding concrete layer.
Excavation from concourse slab level down to upper under platform slab & under platform
slab
The Contractor will use the same work procedure in the excavation for concourse slab explained
above for the excavation of upper under platform and under platform slabs. Telescopic dipper
could be used for removing muck materials out of the excavation pit up to a depth of 30m or
more.

CONTRACT T316
Figure 23: Telescopic Dipper used for Deep Excavation of Station
a). Install Retaining Diaphragm wall b). Excavate below strut and install strut
before excavation commences. and preload to support the retaining
walls, which in turn support the soil at
the sides.
d).Backfilling and the next level of slab is

c). Construct roof slab with access, with
constructed, and this process
access openings provided on the slab
progresses downwards till the base
for works to proceed downwards.
slab is completed
e). The side walls are constructed, f). After underground structure is
followed by removal of the completed, backfill soil to top strut level
intermediate struts. The access prior strut removal and reinstate the
openings on the roof slab are then surface area.
sealed.
Figure 24: Sequence Work for Top down Excavation

CONTRACT T316

CONTRACT T316
Bottom up Method
The bottom up excavation procedure will commence at the entrance B when all preparatory works,
e.g. ERSS wall (D-wall), ground improvement and piles have been completed including the required
operational recharge well and dewatering system.
The excavation works is carried out by using excavator with the help of loaders from the existing
ground up to 1.0m below the `first level strut S1 and then subsequently strut S1 is installed. The
installed strut S1 will undergo preloading.
All the excavated soils are loaded directly into dump trucks to bring and dump the loads to approved
dumping areas.
The excavation will commence after preloading of strut S1 up to 1.0m below strut S2 level and then
the strut S2 is installed and preloaded. As this time the excavation area may be blocked by the
installed struts as the excavation depth increases, consequently excavation works would become
unviable using standard size excavator.
Therefore the Contractor will carry out the excavation by bringing down smaller size excavators,
small size loaders and smaller size dump trucks into the bottom of excavation pit to undertake the
excavation works.
The smaller size excavators will excavate the soil and load the soil to small dumpers to bring the
load beside the D-wall.
The telescopic dippers stationed at the brink of D-wall will lift up the excavated soil out of the pit and
load the same to dumpers for disposal. Small size loaders will help the loading works and be used
for making and leveling the temporary route of small size dumpers hauling the loads to the side of
D-wall.
The excavation and the installation of strut in stages will continue until reaching the required
formation level as per the requirements of drawings, technical specifications and to the satisfaction
of the Engineer.
All the earthwork equipments brought down are lifted up out of the excavation pit. The final formation
level is compacted to required compaction and the base slab is poured afterward.
Then the strutting frame will be removed in stages starting from bottom to top in order to facilitate the
pouring of remaining structure until roof slab.
If rock and water are encountered during the excavation, the rock excavation procedure and
dewatering system explained in the top-down procedure is adopted respectively.
The Bottom –up excavation works is illustrated on the drawing below:

CONTRACT T316

CONTRACT T316
Proposed Equipment and Anticipated Cycle Time for Excavation
Table below shows the output capacity of the various proposed major equipment proving their
suitability and reliability for the work.
Estimated
Quantity
(Capacity)
per Day
2~3 nos.
1 Hydraulic Excavator for excavation
(1.1 m3) Above
400 m3 /day Roof
10~15 nos. Slab
2 Dump Truck for hauling
(15 ton)
2~3 nos.
3 Long Boom Excavator for excavation
(1.5 m3)
8~12 nos.
4 Hydraulic Excavator for excavation
(0.5 m3)
2~3 nos. Under
5 Telescopic Dipper for deep digging 300 m3 /day Roof
(0.9 m3) Slab
Transporting 2 nos.
6 Uni Loader materials from
limited space (0.48 m3)
8~10 nos.
7 Dump Truck For hauling
(15 ton)
Concrete for Station and Entrances
The scope includes the construction of reinforced concrete substructures multi-storey Station,
Entrances and Shafts including waterproofing and backfilling. All preparatory works, i.e., ERSS,
ground improvement, excavation, dewatering and compaction in correct alignment and level will be
carried out as explained above in the previous sections of this method statement.
The main structural works will only commence once all prerequisite works mentioned above have
been completed as per the approved construction drawings and specifications and approved by
Engineer.
If water is present in the excavation, dewatering will be maintained during the execution of work
controlling the groundwater level at least 0.7 m below the lowest formation level or as prescribed in
the specifications at particular work area of work to keep the formation level in dry condition at all
times.
The installation, operation and maintenance of the dewatering system will be carried out prior to deep
excavation work. After finishing the structural concrete works (roof and under platform slabs),
application of waterproofing for roof slab and above blinding concrete for under platform slab may
proceed. After then, the structure will be backfilled by suitable fill in layer up to final ground level.

CONTRACT T316
Concrete Works
The concrete works is carried out according to the specifications or as instructed by the Engineer.
The Work will be under strict compliance with the Quality and SHEM management. Concrete will be
in accordance to approved mix designs.
Mix Design
All concrete grades are designed according to the specification and be verified by trial mix. The
results of selected concrete trial mix which meets all of the specification requirements will be
submitted to the Engineer for Approval. The mix design will be as per LTA specifications. The
specified mix designs of concrete are the following:
Element Concrete Grade

D-walls or Piles C32/40
Roof & Base Slabs C32/40
Internal Slabs, Walls & Columns C32/40

Above Ground Structures C32/40
Non- Load Bearing Internal Walls C28/35

Track First Stage Concrete C25/30
Blinding concrete C12/15
Supply of Concrete
The Contractor will use ready mixed concrete for all concrete works. The concrete will be transported
from batching plant to construction site by concrete transit mixers/agitators and placement by
concrete pumps.
The Contractor shall produce concrete from approved ready mixed suppliers operating nearby the
site. Approval from the Engineer must be obtained from the various design mixes of concrete prior
to production of concrete to be used on site.
Concrete construction
Blinding Concrete
Unless otherwise stated, blinding concrete (Grade C16/20) at least 75 mm thick will be provided on
soil surfaces forming the underside of reinforced concrete slab.
The Contractor will allow for increased blinding thickness or strength depending on soil conditions
and surface irregularities. Blinding concrete will be poured on the top of the compacted trench or of
the formation level for the reinforced concrete substructures ground slab to set on.

CONTRACT T316
Approval from the Engineer for design mix of blinding concrete will be taken prior to any pouring at
the designated location.
The mix design will be based on the requirements in the technical specifications. The compaction of
the formation level will be checked and approved by the Engineer prior to pouring of blinding concrete.
Construction/ Expansion/ Contraction Joints
All joints at the concrete structure should be according to the design or according to the approved
construction shop drawing. Where construction joint (CJ) are not shown in the drawings, the
Contractor will submit proposals to the Engineer for approval prior to commencing works.
Construction joints are located at approved locations and the sequence of placing is arranged as
approved, or as shown on the drawings to minimize shrinkage and thermal strains in the concrete.
Horizontal construction joints in walls are formed along straight lines coinciding with the full height of
the formwork or as prescribed or detailed in the construction drawing. Construction joints will be
formed normal to the surface of the retained concrete.
A retarding agent with the approval from Engineer is used on the construction joints and the laitance
removed prior to the next concrete pour using appropriate methods. All traces of retarding agent are
removed prior to subsequent pours.
The use of construction joints are avoided when possible where they are in addition to the approved
pour sequence design. The contraction/expansion joints are constructed on the specified locations
as indicated on the construction drawing.
All joint materials associated in the works are installed and checked prior to concrete pouring in
accordance to the pertinent drawings and technical specifications approved by Engineer.
Lift Height of Concrete
The permissible depth of concrete placed in one lift is as described below unless otherwise shown
on the Drawings or directed by the Engineer.
The permissible depth of concrete placed in one lift is 1.50 m where the concrete is cast on bedrock
and / or the thickness of base slab and wall exceeds 3.00 m.
The concrete directed dropped height should not be greater than 1.00 meter. The details of concrete
lifts should be according to the approved concrete lift drawing or as per the instructions of the
Engineer.
Concrete Work Procedure
The general sequence and procedure for pouring of concrete on the top of blinding concrete for

CONTRACT T316
ground slab will be as the following: Survey and marking of structural member, fix the reinforcements,
install the embed parts (MEP), install the formwork, pouring the concrete. Before pouring the
concrete, the pouring fronts will be checked and approved by the Engineer.
Concrete Workmanship
Formworks
The materials used for fabrication of formworks will be of good quality to produce robust formworks.
The surface of formwork should meet the requirements as stipulated in the particular specifications.
The formwork fabrication and installation will need to meet the requirements of the specifications. All
formworks and supports will be strong and firm enough. Joints will be mortar-tight and sufficiently
strong to withstand loads of concrete, labor, equipment and other imposed loads.The ties or anchors
for fixing formwork will not be bent. Connection of ties and anchorage will be firmed and have enough
anchorage in enduring loads.
The period of time elapsing between the placing of the concrete and the removal of formworks will
be according to requirements as specified in the Technical Provisions.
The Contractor will adopt the two kinds of formworks method:
System Forms
The Band 2 category for the sytem formwork will be adopted by the Contractor for both
horizontal and vertical formworks. The Peri’s Trio or Vario panel type systemform or other
brand of the same principle will be used for the station construction.
Figure 25: Panel type-1 System Form

CONTRACT T316
Figure 26: Panel type 2 System Form
The following advantages of the systemforms are:
● High speed of erection (works’ execution speed increases) and as a result, rapid
completion of the project - considerable saving of time;
● Minimal use of a crane, as formwork is lifted by hydraulic jacks;
● Optimal quantity of scaffolding and work platforms as the slip formwork system
presupposes the use of its own platforms for implementation of works. This helps to
maintain cleanliness and order at the construction site, because there is no redundant
material to be stored;
● Uniformity of wall sections with the project drawings, smooth wall surfaces are
achieved by the use of slip formwork, which cannot be said about other formwork
systems;
● Reduced labor costs due to the intensity of the working process.
Currently system form suppliers are widely available in Singapore and that finding the
appropriate contractor will not be difficult.
Steel or Euro forms
The following advantages of the Euroforms are:
● Easy to install and to dismantle for the reinforced concrete construction in any type.
● The structure of the panels is conveniently designed for various functions, enabling
the panels to be reused repeatedly, helping save the costs on materials and reduce
the times for work by simplifying and accelerating the process.
● Consequently it can cut down on the labor costs and expenses. Basic and standard
products as well as various products for different types and sizes of constructions are
available from manufacturing.
● Recycling the panel after its life-span can help reduce costs.

CONTRACT T316
Reinforcement
The Contractor will purchase all reinforcement

(fy = 500 Mpa) in batches in accordance to
reinforcement detail drawings, design
documents and construction time plan. All steel
reinforcing bars are then stored after testing
and approval. The storekeeper will mark the
batches according to different grade,
trademark, type and manufacturers.
Each batch of steel bar will meet the

requirements of Specifications. Unqualified products will not be allowed to be delivered to site.
Reinforcement cut and bent to BS 4466 in workshop will be according to shop drawings and
specifications and be transported to site by trucks after manufactured. Lifting to working fronts will
be made by mobile crane or manpower and fixed manually.
The reinforcement steels are fixed according to the reinforcement detailed drawings. The cover to
the reinforcement should be maintained by concrete spacer blocks. The concrete blocks should be
approved by the Engineer.
Prior to concrete placement and / or during concrete placement, the positions of reinforcement should
be kept to the correct positions. It is not allowed to shift or cut the reinforcement steel for convenience
of concrete placement.
Embedded Parts
Embedded parts, mechanical, electrical and plumbing (MEP) including expansion/ contraction/

CONTRACT T316
construction joint materials, approved by Engineer will be embedded according to the drawings.
Attention will be paid to concrete around embedded parts during concrete placement to ensure no
movement or damage created resulting from pouring. Prompt correction will be made when there
appears distortion or moving of the embedded parts.
Joints Treatment
When the concrete is to be cast on place, the area should be cleaned and kept wet and all loose
materials and refuses should be removed. If the concrete is placed against the existing concrete or
the concrete has reached the design strength, the joint should be high-pressure water blasted. The
joint should be roughened to the requirement of construction joint.
The clearance for one lift concrete placing should be according to the approved drawings or as
instructed by the Engineer.
The use of construction joints will be avoided if possible where they are in addition to the approved
pour sequence design.
Concrete Transportation
Concrete is transported by concrete transit mixers/trucks, which prevent contamination, (by dust, rain
etc.) segregation or loss of ingredients, excessive evaporation and loss of consistency. Concrete is
transported and placed without delay, as is reasonably practicable.
All equipments used for the placing of concrete are kept clean.
The timings of delivery to pouring areas are checked and maintained as per technical specifications
to avoid over mixed concrete and initial setting of concrete that may cause unwanted construction
joints on poured concrete.
Concrete Spreading and Compaction
Concrete is completely discharged within specified time. Temperature of concrete at time of

discharge will not exceed the specifications. Concrete mixed will not be modified by the addition of
water or otherwise in order to facilitate handling or for any other purposes.
Concrete will not be dropped into place vertically in great height to avoid segregation. It will not be
allowed to strike the formwork hardly between the point of its discharge and its final place. Concrete
will not be dropped freely through a height greater than 1.00 m and all concrete will be placed using
concrete pumps.All concrete are compacted with power driven, immersion type vibrators
supplemented by hand spading and tamping.
The vibrators are inserted into the un-compacted concrete vertically and at regular intervals such
that the radius of action overlaps that of the previously vibrated concrete. A layer is not covered with
a succeeding layer until it has been thoroughly vibrated as specified. Where the uncompact concrete

CONTRACT T316
is in a layer above freshly compacted concrete, the vibrator should penetrate vertically for about 100
mm into the previous layer.The vibrators will is not allowed to come into contact with the formwork
or embedded parts, nor will they be withdrawn quickly from the mass of concrete, but will be drawn
back slowly so as to leave no voids.
Care is taken properly to vibrate concrete placed in contact with previously placed concrete or
embedded parts. The duration of vibration is limited to that required to produce satisfactory
compaction without causing segregation.
Compaction of the concrete by vibration will be such as to produce a concrete that has the maximum
practicable density and is free from pockets of coarse aggregate and entrapped air and makes
complete contact with the foundation, previously placed hardened concrete, embedded items and
the formwork.
Curing of Concrete
Concrete is cured by approved methods for a continuous period as specified in the Specifications or
until covered by the next lift or as otherwise approved by the Engineer. The curing methods will
include but not limited to the following:
water sprays in continuous operation;
covering with hessian cloth or similar absorbent material, or sand, kept constantly wet;
after thorough wetting, covering with a layer of waterproof fabric kept in contact with the
concrete surface;
applying non-staining liquid curing membrane or curing compound approved by Engineer
Temperature Control of Concrete
The maximum temperature of concrete at placement should be controlled within the limits as
prescribed in the specifications. The core temperature should be within the desired range and be
monitored accordingly.
When the temperature of fresh mixed concrete exceeds specifications with the consequence that
workability is adversely affected, mixing and placing of the concrete in question will be terminated.
Special precautions will be taken to ensure the concrete temperature at placing is maintained. These
precautions may include:
Protecting all aggregate stockpiles, water lines and tanks as well as the mixer from the
direct rays of the sun.
Mixing water cooled by the addition of ice to the storage tanks.
Concreting carried out during the cooler parts of the day or during the night.

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Cooling all chutes, formwork and reinforcement by watering when possible, or otherwise
protecting the site of placing from the direct rays of the sun. Any water ponding will be
removed before placing the concrete in the formwork.
Providing wind shields during periods of drying winds.
Precast Concrete Work
General
The Contractor shall inform the Engineer in advance prior to any precast concrete works. The
manufacturing of precast such as staircase, manholes, etc. will be carried out with the same
constituent materials as used in site cast concrete with the consent of the Engineer.
A copy of all cube test results relating to the work shall be sent to the Engineer for acceptance prior
to the installation of the precast element. Where tests are required on pre-cast members, the
members subjected to testing shall not be delivered to site until the tests have been satisfactorily
completed.
Handling and Storage
The Contractor is responsible for designing all methods and equipment for handling, lifting and
installation of the precast concrete elements. Regions in which the precast elements are to be lifted
or supported will be indicated on the Drawings and the units shall not be lifted or supported at any
other points without the prior acceptance of the Engineer.
Suitable holes, grooves, bolts or other lifting devices shall be provided at all lifting points to ensure
the accurate placing of lifting tackle.
Contractor will carry out all temporary penetrations, coverings, lifting devices in accordance with the
requirements of the Engineer.
Protection
The Contractor will be properly protects the precast units at all stages of construction to prevent
damage or staining of permanently exposed concrete surface.
Assembly and erection
The Contractor will strictly adhere on site the approved method of assembly and erection. Also, the
Contractor will provide temporary supports after the pre-cast units are lifted into position and the
structural connections shall be completed as soon as possible.
Precast unit Load Test
Samples of the precast unit for the tests shall be provided and delivered by the Contractor to the
approved Singapore Accreditation Council (SAC) accredited laboratory.

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For precast concrete members which shall subsequently form parts of composite members, any of
the following methods may be used at the discretion of the Engineer:
● The precast member may be tested along with a load system equivalent to that
producing the most critical conditions in the composite members.
● The precast member may be made equivalent to the final composite member by
casting the relevant amount of in-situ concrete, and then tested as a composite
member.
Dewatering of Site due to Rain
In the event of unexpected heavy rain during concreting which may cause accumulation of unwanted
waters on the site, standby submersible pumps will be used to dewater the working areas affected.
Temporary dewatering system will be in function during this eventuality where required. Pump
operators will be available round-the-clock until unwanted waters are completely removed out of site.
Waterproofing Work Procedure
The Contractor will apply the waterproofing membrane as per the schedule indicated on the pertinent
drawings. The materials will be a product of known manufacturer possessing high quality and
approved by the Engineer.
The waterproofing should be compatible with the face finishing of the concrete. Contractor will fully
follow the manufacturer’s instruction on how to apply waterproofing membrane. The surfaces will be
thoroughly cleaned prior to application of waterproofing membrane. Approval of Engineer will be
sought prior and after the application of waterproofing.

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Fabrication and Installation of Steel
Introduction
In this section the importance of fabrication and erection in structural steelwork is underlined. The
various tasks involved in fabrication are discussed.
The joints, which are important components in structural steelwork, are explained, with a special
emphasis on welded joints. Some aspects of erection of steel structures are also presented.
Thus an overall view of the fabrication and erection of structural steelwork for the Katong Park Station
entrances is covered.
Fabrication Procedure
Structural steel fabrication can be carried out in shop or at the construction site by the Contractor.
Most fabrication of steelwork will be carried out in shops especially those which require more
precision work.to assure quality. And the rest for steel work fabrication can be done in the field in
which the Contractor approved but still observing the quality outcome.
Structural steel will go through various operations during the course of its fabrication. Generally, the
sequence of activities in fabricating shops is shown in Table 4: Sequence of Activities in Fabrication
Shops.
The sequence and importance of shop operations will vary depending on the type of fabrication
required. All these activities are explained briefly in the subsequent parts of the section
Table 4: Sequence of Activities in Fabrication Shops
S.No. Sequence of Operation
1. Surface cleaning
2. Cutting and machining.
3. Punching and drilling
4. Straightening, bending and rolling
5. Fitting and reaming

6 Fastening (bolting, riveting and welding
7 Finishing
8 Quality control
9 Surface treatment
10 Transportation

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Surface cleaning
Structural sections from the rolling mills may require surface

cleaning to remove mill scale prior to fabrication and painting. The
Contractor considers the blast cleaning as the accepted way of
carrying out surface preparation in a well-run fabrication shop.
Abrasive particles are projected on to the surface of the steel at high
speed by either compressed air or centrifugal impeller to remove
rust and roughen the surface before applying the coating.
By using shot or slag grits, both of which have an angular profile, Figure 28: Surface Cleaning
surface oxides are removed and a rougher surface is obtained to
provide an adequate key for metal spraying or special paint. Surface contaminants on the rolled steel
surface, such as oil and grease are undesirable and must be removed before the blast cleaning
process. Other method that the Contractor is considering is the flame cleaning. In this method the
surface is cleaned using an oxy-acetylene torch which works on the principle of differential thermal
expansion between steel and mill scale. In another method called the steel piece is immersed in a
suitable acid and the scale and rust are removed.
Cutting and Machining
Following surface preparation, cutting to length is always the first process to be carried out, and this
is done by any of the following methods.
Shearing and cropping
Sections can be cut to length or width by cropping or shearing using hydraulic shears. Heavy
sections or long plates can be shaped and cut to length by specialist plate shears. For smaller
plates and sections, machines featuring a range of shearing knives, which can accept the
differing section shapes, are available.
Flame Cutting or Burning
In this method, the steel is heated locally by a pressurized mixture of oxygen and a combustible
gas such as propane, which passes through a ring of small holes in a cutting nozzle. The heat
is focused on to a very narrow band and the steel melts at 1500 ºC when a jet of high-pressure
oxygen is released through a separate hole in the center of the nozzle to blast away the molten
metal in globules.
The desired cuts are obtained quickly by this process. However due to a rapid thermal cycle of
heating and cooling, residual stresses and distortion are induced and hence structural sections
that are fabricated using flame cutting are treated specially in the design of structural steelwork.
Cold Sawing

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When a section cannot be cut to length by cropping or shearing, then it is normally sawn. All
saws for structural applications are mechanical and feature some degree of computer control.
There are three forms of mechanical saw - circular and hack. The circular saw has a blade
rotating in a vertical plane, which can cut either downwards or upwards, though the former is
more common. Hack saws are mechanically driven reciprocating saws. They have normal
format blades carried in a heavy duty hack saw frame.
Punching and Drilling
The radial drill which is a manually operated machine is

used to form holes for connection in structural steel
work. If the radial drill is not sufficient to meet the
requirements, the Contractor has the option to install NC
(Numerically Controlled) tooling which registers and
drills in response to keyed in data which can drill many
holes in flanges and webs of rolled steel sections. This
can also use to punch holes. Figure 29: Punching & Drilling
Smaller size (2 mm to 4 mm lesser than final size) holes are punched and subsequently reamed to
the desired size in order to reduce the effect of strain hardening and the consequent reduction in
ductility of material
Straightening, Bending and Rolling
Rolled steel may get distorted after rolling due to cooling process. Further, during transportation and
handling operations, materials may bend or may even undergo distortion. This may also occur during
punching operation. Therefore before attempting further fabrication the material should be
straightened. Either rolls or gag presses will be used to straighten structural shapes by the Contractor.
Gag press is generally used for straightening beams,

channels, angles and heavy bars. Long plates, which
are cambered out of alignment longitudinally, are
straightened by rollers. They are passed through a
series of rollers that bend them back and forth with
progressively diminishing deformation. Misalignments
in structural shapes are sometimes corrected by spot
Figure 30: Gag Press machine
or pattern heating. This method is commonly employed
to remove buckles in girder webs between stiffeners and to straighten members. It is frequently used
to produce camber in rolled beams.
Fitting and Reaming

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Before final assembly, the component parts of a member are fitted-

up temporarily with rivets, bolts or small amount of welds. The fitting-
up operation includes attachment of previously omitted splice plates
and other fittings and the correction of minor defects found.
In riveted or bolted work, especially when done manually, some holes

in the connecting material may not always be in perfect alignment
and small amount of reaming may be required to permit insertion of
fasteners. In this operation, the holes are punched, 4 to 6 mm smaller
than final size, then after the pieces are assembled; the holes are Figure 31: Fitting & Reaming
reamed by electric or pneumatic reamers to the correct diameter, to
produce well matched holes.
Fastening Methods
There are three methods of fastening namely bolting, riveting and welding. Welding is the most
common method of shop fabrication of steel structures since it is simple. Welded connection
considerably reduce the size of the joint and the additional fixtures and plates.
Other structural members which are low temperature performance are to be bolted to avoid welding
stresses, distortion or the requirement for the component to be taken apart during service e.g. bolts
in crane rails or bolted crane rails.
Finishing
The term finish or mill is used on detail drawings to describe any operation that requires steel to be
finished to a smooth even surface. Structural members whose ends must transmit loads by bearing
against one another are usually finished to a smooth even surface. Finishing is performed by sawing,
milling, planning or other suitable means.
Surface Treatment
Structural steelwork is protected against corrosion by

applying metal or paint coating in the shop or at site.
The commonly used methods of applying metal

coating to steel surfaces are hot-dip galvanizing,
metal spraying, and electroplating. Electro-plating is
generally used for fittings and other small items.
Painting is the principal method of protecting structural

steelwork from corrosion. Figure 32: Metal Coatings

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Paints are usually applied one coat on top of another,

each coat having a specific function or use.
The primer is applied directly on to the cleaned steel

surface followed by the intermediate coats (or
undercoats) which are applied to build the total film
thickness of the system.
Lastly the finishing coats will be applied which provide

the first-line defense against the environment and also
determine the final appearance in terms of gloss, color
etc. Materials to be used for surface treatment will be
in accordance to specification requirements. Figure 33: Paint Coatings
Welded connections
Welding is used extensively for joining metals together and there are five welding process regularly
employed by the Contractor for this work namely:
● Shielded Metal Arc Welding (SMAW)

● Submerged-Arc Welding (SAW)
● Manual Metal-Arc welding (MMA)
● Metal-Active Gas welding (MAG)
● Stud welding
Quality Control in Fabrication
Quality control during fabrication assumes utmost importance in ensuring that the completed
structure behaves in the manner envisaged during design stage.
Any deviation from these design considerations as reflected in detail drawings may cause additional
stresses to the structure and affect its strength and durability. This section discusses the relevant
aspects in fabrication and erection, which need to be considered to achieve the desired quality.
A fabricator's work starts from the point of procurement of raw materials including fasteners and ends
with the dispatch of the fabricated items to site for erection.
In order to ensure that the fabrication can be carried out in accordance with the drawings, it is
necessary that inspection and checking is carried out in accordance with an agreed Quality
Assurance Plan (QAP).
The QAP should elaborate on checks and inspections of the raw materials and also of the
components as they are fabricated, joined etc.
Fabrication activities have increased steadily in yards adjacent to work site. In the absence of

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controlled environment (as in an organized workshop), the quality of workmanship of such fabrication
is likely to suffer.
Therefore it has become more important to motivate the fabricators to appreciate the usefulness of
Quality Assurance Plans and introduce the system in all their works and at site as well.
Managing the Risk during Fabrication Stage
The key risks involved in steel structural fabrication, and the controls for each of these are outlined
below:
Common Hazard
Incomplete or inaccurate shop drawings
Collapse of structure due to element failure
Members not clearly marked or identifiable
Weld failure due to poor quality or lack of testing
Incomplete fabrication (missing components)
Fabrication errors (angles, etc).
Risk Control
The fabricator must:
ensure strength of members by using grades of steel which are in accordance with the
relevant standards prescribed in the technical specifications
ensure shop drawings comply with structural design drawings and include the following
information:
● the date and issue number

● the project location
● the structural design criteria affecting construction
● plans and elevations indicating the structural framing, layout and orientation
● clear identification and numbering of members
● structurally critical dimensions
● where appropriate, the tolerance limits on the element
● the specifications and location of bracing or temporary supports
● the requirements and locations for framing connections
● the requirement for concrete foundations and base connections
● the requirements for lifting and location of any lifting points
● rigging details (for components that cannot be conventionally slung)

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● ensure components are manufactured in accordance with specifications

● ensure weld tests as per requirements
● design approval by the structural design engineer.
Erection Process for Steel
General
The erection of steel structures will be carried out by the Contractor by which the fabricated structural
members are assembled together to form the skeletal structure. Generally the steps in the erection
of steel structures are shown in Table 1.
Table 5: Sequence of Activities during Erection
S.No. Sequence of Operation
1. Receiving material from the shop and temporarily stacking them, if necessary.
2. Lifting and placing the member and temporarily holding in place.
3. Temporarily bracing the system to ensure stability during erection.
4. Aligning and permanently connecting the members by bolting or welding.
5. Connecting cladding to the steel structural skeleton.

6. Application of a final coat of painting.
The erection process requires considerable planning in terms of material delivery, material handling,
member assembly and member connection.
Safe transportation of fabricated items to the site, their proper storage and subsequent handling are
the pivotal processes for the success of fabrication of structural steel work.
Proper planning of material delivery would minimize storage requirement and additional handling
from the site storage, particularly heavy items.
For the safe and accurate erection of structural steel work for station entrances, temporary support,
false work, staging etc. are erected.
Before erection the fabricated materials should be verified at site with respect to mark numbers, key
plan and shipping list.
The structural components received for erection should be stacked in such a way that erection
sequence is not affected due to improper storing. Care also should be taken so that steel structural
components should not come in contact with earth or accumulated water.
Stacking of the structures should be done in such a way that, erection marks and mark numbers on
the components are visible easily and handling does not become difficult.
Handling and storage

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The fabrication at shop or site should be so planned that units to be handled weigh nearly the same.
The erection drawing should reach the site of construction well in advance to plan the erection
sequence and material handling.
Erection should be carried out with the help of maximum possible mechanization. Normally anyone
or more of the material handling systems, such as tower crane; crane mounted on rails, crawling
crane, pneumatic tire mounted crane, and derrick crane may be used for handling the material.
Definite equipment to be used will be decided on site.
A variety of methods can be employed for the erection of a structure. Normally, the selection of the
method is influenced by the type of the structure, site conditions, equipment, quality of skilled labor,
etc. available to the erector.
However, regardless of the method adopted the main aim during erection is the safety and
preservation of the stability of the structure at all times.
Before the commencement of the erection, all the erection equipment tools, shackles, ropes etc.
should be tested for their load carrying capacity. Such tests if needed may be repeated at
intermediate stages also.
Bracings
During the entire erection period, the steelwork will be securely bolted or otherwise fastened and
braced to take care of the stresses from erection equipment or the loads carried during erection.
In addition to this, adequate provisions to resist lateral forces and wind loads during erection will also
be made according to local conditions.
Normally bracings are built into all types of structures to give them a capability to withstand horizontal
forces produced by wind, temperature and the movements of crane. Temporary bracings required at
some stages of the work will have properly designed connections and will be specifically referred to
in the erection method statement.
The decision on sequence of erection such as which member will be erected first for providing initial
stability to the structure or whether temporary bracings should be used for this purpose will be taken
at an early stage of planning of the erection process. Figure 34: Bracing System Illustration.
As permanent bracings have been provided in AB, bay erection should logically start from AB bay to
give stability and ensure proper alignment of the erected structure.
In case, for some reason erection has to start from DE bay, it would be necessary to provide
temporary bracings in this bay. The bracing system should be retained till the permanent bracings
are fixed in the AB bay. Any misalignment at initial stage will impair the performance, of the structure
when completed. Early or unauthorized removal of temporary bracings is a common cause of

CONTRACT T316
collapse in a partially completed frame.
Having considered the need for installing temporary bracings and the need to postpone fixing
permanent bracings, consideration will be given to the overall economy of retaining the temporary
bracings and perhaps leaving out the permanent bracings.
It is a costly and potentially dangerous business to go back into a structure solely in order to take out
temporary members, or to insert components that had to be left out temporarily.
A B C D E
Figure 34: Bracing System Illustration
Maintaining tolerances
The best way of erecting a structure within the acceptable tolerance limits is to make sure that
accuracy is achieved from the very beginning of the job.
Thus quality control must start from the setting out of the foundations and the holding down bolts.
This operation is often done at a stage when site conditions are disorderly and most untidy and the
environment appears to be incongruous to accuracy.
However, inaccuracies in marking the center lines and the levels of foundations allowed at this stage
are likely to cause misfit in the connections and misalignment of the structure leading to secondary
stresses in the members.
In such areas corrective measure must be taken by way of locally modifying some of the components
so as to eliminate the mismatch.
Table 6: Maximum permissible tolerance in erected steel structures shows some typical tolerances
that are accepted in structural steel work.
Table 6: Maximum permissible tolerance in erected steel structures

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S.No. Description Tolerance in(mm)
1. Columns:
Out of plumbness of column axis from
true vertical axis
a) Heights up to 30 m ±l/1000 or 25 whichever is less
b) Heights over 30 m ±l/1200 or 35 whichever is less

2. Trusses: ±10
Lateral shift in location of truss from its

true vertical position
3. Crane girders and ribs: ±5
Shift in plane of alignment with respect

to true axis of crane rail.
Joints
Most steel structures are fabricated by either bolting or welding in the shop and bolting or welding in
the field. Durability of a structure largely depends on the quality of the joints made at site.
In bolted connections, care should be taken to ensure that all parts intended to be bolted together
should be in contact over the whole surface and the surfaces should be thoroughly cleaned and
painted with specified primer paint and the two matching plates or sections secured together while
the paint is still wet by service bolts.
After erection, the joint should be made by filling not less than 50% of the holes with bolts. The
service bolts are to be tightened. The holes that need enlargement to admit bolts or rivets should be
reamed only after carefully examining the extent of the inaccuracy and the effect on the soundness
of the structure. Such holes must not be formed by gas cutting process.
For connections to be done by welding the components should be securely held in position to ensure
alignment, camber etc., before welding is commenced. In the case of field assembly using bolts the
number of washers for the permanent bolts should not be more than two (and not less than one) for
the nuts and one for the bolt head.
It is desirable to use wooden rams and mallet to force the members in position so as to protect
steelwork from injury and shock. It should also be ensured that the bolts project through the nut by
at least one thread. In the case of field assembly by welding almost all the precautions needed for
shop welding may be followed.
In the case of High Strength Friction Grip (HSFG) bolts the material surfaces should be absolutely
free from grease, lubricant, dust, rust etc. and shall be thoroughly cleaned before assembling. The
nuts will be pre-tensioned by a torque–wrench or by the turn of the nut method with the help of

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pneumatic wrench/lever. After tightening the bolt heads, nuts and edges of the mating, surfaces
should be sealed with a coat of paint to obviate entry of moisture. In the case of connections such
as base plate they must be aligned and levelled using wedges/ shims and subsequently filled by
grouting.
Managing Risk during Erection Stage
The Contractor should ensure that the accuracy of each work is within the tolerance of the level or
position designed by the relevant requirement. Any modifications of the relevant erection also need
to be checked by the Contactor after Engineer’s approval.
The key risks involved in steel erection ad the controls for each of these are outlined below.
• Falling from a height rigging

• Falling objects
Common Hazards • Collapse of the structure during construction

• Being struck by plant
• Plant contacting underground or overhead utility services
• Being struck by an objects such as steel members
• Reduce the need for work height

• Reduce the risk from falling objects
• Ensure a sequential erection procedure as per marking plans
• Oversee the implementation of the sequential erection procedure by
experienced steel erection supervisor at all times
• Ensure an adequate exclusion zone to prevent risk to other people
• Ensure the structure’s stability is available and being used
• Ensure temporary guys or bracing are securely anchored
Risk Controls • Verify the stability of the structure in accordance with the Specifications
• Check the fittings for the support to ensure adequate structural capacity
• Protection of the public that may affect a crane load
• Check the type and amount of packing under the crane’s outriggers
• Availability of written procedures for setting up and dismantling of the
crane/lifting method
• Identify all utility services before any crane work on site
• Ensure permission from the utility company, work is not carried out closer
to the services than 3 meters in the case of an underground asset
registered under the Pipelines

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Instrumentation and Monitoring
Ground movement will is monitored at all times prior, during, and after construction to ensure there
is no unnecessary movement in the soil.
The Contractor will keep close connection with the other contractor who will be the instrumentation
specialist to make sure that all installed instruments are not damaged and all measurements can be
recorded accordingly.
The work area within the work of influence, including the tunnels, will be monitored. The Contractor
will take special interest in monitoring the following area where the control of ground movement will
be very critical.
Station and Tunnel Interface
Tunnel Sump
Cross Passage
Cross Passage shaft
Building Protection
Planned TBM Cutter Head Intervention (CHI)
The Contractor will make coordination, the adjacent Civil Contractors and agreed with the Engineer
and the respective QP(S) the monitoring frequencies at the interfaces.
Protection to Adjacent Buildings or Structures
Close proximity to existing Buildings
The Contractor is aware that the construction for the station is in close proximity with some existing
buildings in the area.
The Contractor will put his attention during the station works for the following existing affected
building/structures namely:
a) The Line Condo and the;
b) DTSS Link sewer.
The Contractor will make sure that during construction, existing buildings/ structures will be properly
protected and that necessary protection shall be implemented to preserve their integrity and prevent
them to any damages during work execution to the station. Existing buildings/structures shall always
be taken into consideration when any work method is being implemented onsite the Contractor.
The Contractor shall liaise with the owners and tenants of any building/structures affected by the

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Works.
The Contractor shall be responsible for any repair and reinstatement required during and after
completion of the works. Below succeeding section details the impact of the work as well as the
necessary protection to adjacent buildings/ structures.
Impact of Construction Activities to Adjacent Existing Structures
Construction activities can impact adjacent structures in three general modes: by direct contact, by
causing ground movement, and by inducing ground vibrations.
These modes and the associated construction activities are discussed below.
Direct Contact
The damage resulting from direct contact by construction equipment in motion can be severe.
Severe damage can also result during mechanical demolition of existing onsite structures
directly connected to adjacent structures.
Although severe, such damage is usually local. However, in past rare incidences, gross
negligence during equipment operation, lack of equipment maintenance or improper erection of
cranes, and improper demolition design and/or means and methods have led to severe and
more widespread damage to adjacent structures.
Ground Movement
Ground movement can be defined as unintentional movement or removal of soil or rock from
beneath a structure resulting in its movement or loss of support.
Ground movement can occur during site excavation, temporary excavation support, site
dewatering, etc. The obvious result is settlement of adjacent structures, which further results in
cosmetic or structural damage and even collapse, depending upon the magnitude of settlement.
Ground Vibrations
Low Magnitude, but Sustained Vibrations
Low magnitude vibrations, that when instantaneous would not result in direct structural damage
to adjacent buildings, can cause densification of loose or medium dense granular soils beneath
adjacent structures over time. As a result, shallow-foundation-supported adjacent structures can
undergo settlement, which can lead to their cosmetic or structural damage depending upon the
settlement magnitude. Pile driving and rock excavation using hoe rams are examples of typical
construction activities that can result in low magnitude sustained vibrations.
Large Magnitude Vibrations
Activities such as, pile driving, and rock excavation using hoe rams when performed in close

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proximity to the adjacent structures can induce high vibration levels into the soil and rock
supporting these structures. Depending upon the natural frequencies of the adjacent structures,
and the frequency and magnitude of the induced vibrations, the adjacent structures can likely
sustain various degrees of direct structural or settlement induced damage.
Protective Measures to adjacent Structures
General
The Katong Park station have been planned to avoid disturbance or damage during construction to
neighboring buildings and other structures wherever possible. However, there are a few areas where
this cannot be avoided. In addition, in some other areas, existing buildings/structures would be very
close to excavation sites or (the tunnels’ alignment) such as the Line Condo and the DTSS.
The ground condition of these nearby or adjacent buildings and structures are prone to certain degree
of effect due to the substantial earthworks to be carried out in the site.
The buildings and structures nearer to the site will be subject to geotechnical and structural effect
such as:
Ground Settlement
Building Settlement
Tilting
Deformation
In these and certain other cases, a variety of measures, grouting and building external support frames,
would be used to protect nearby structures during and following construction. While many protective
technologies exist, all of these methods can themselves produce varying degrees of construction
disturbance. The choice of which method(s) to use depends on a number of factors, including:
Proximity of the building to the construction excavation;
Soil conditions;
Groundwater conditions and control techniques;
Foundation types and conditions of existing structures;
Type of structure used;
Type of tunnel method used;
Loads carried by the existing structure;
Dimensions of excavation;

CONTRACT T316
Sequence of construction operations; and
Rock quality.
In most cases, it is not possible to determine which support measures is needed until structural
surveys and soil borings are completed in areas where protective measures is required.
Types of Protective Measures
Following is a brief summary of the types of protective methods that could be employed along the
alignment.
Ground improvement
In isolated cases where the project would require construction in soil beneath existing structures
one type of protective measure that may be employed is ground improvement by “grouting.”
The purpose of a grouting operation would be to increase the strength and decrease the
permeability of the soil near, stations, buildings, or utilities. These techniques have many uses,
among them is supporting building foundations during construction.
Several types of grouting exist, and include:
①. Local grouting—With this method, grouting is more localized, and is limited to activity
in a building’s basement. Work of this sort can be difficult to perform, because of the
limited headroom. In addition, during the grouting operation, there would be restricted
use of the basement space.
②. Jet grouting—This method involves injecting a jet of cement grout at high pressure
through rotating nozzles into the zone of soil that requires improvement. The cement
grout mixes with the native soil to create a form of weak concrete above the roof of the
intended excavation area.
③. The grout is injected from street level through small-diameter (approximately 4-inch)
holes drilled using hydraulic drill rigs. As each hole is completed, the rig would be
moved, and work would commence on another drill hole.
Prohibition of Percussive Piling
For the protection works to the nearby existing structures, Continuous Flight Auger (CFA) piling
method is considered more suitable than the displacement piling or percussive piling for it would
induce less vibration due to driving force and in turn generates less adverse impact on the
surroundings.
Other Protective Measures
Among the other types of supportive measures that could also be employed are the following:

CONTRACT T316
①. External Support Frames—External building frames can be erected around a building’s

façade. While no interior alterations are required, external frames can also leave a
permanent imprint on a building’s façade. While the frames are removed following
construction, during their use, they are unavoidably unattractive, as they obscure much
of a building’s façade.
②. Groundwater Recharge—In circumstances where it is judged that there may be

an unacceptable risk of lowering the groundwater table, which could negatively affect
existing structures, wells may be installed and water pumped into the ground to
maintain the groundwater table at an acceptable level.
Settlement and Other Possible Effects
Even with the measures identified above, some movement or settlement could occur.
Acceptable limits of movement would be determined before construction for each building;
these would be determined based on the foundation design, construction method, and
functionality of each building.
Just before construction, baseline surveys and visual inspections and photographic
documentation would be completed for buildings that are directly adjacent to the alignment
to establish and document the pre-construction condition.
During construction, a geotechnical instrumentation program would be used to monitor the

performance of braced excavations and the identified critical structures; his program would
be conducted during construction.
Installation of monitoring system and checkpoints
The performances of the protective measures have to be checked by a monitoring system

in which checkpoints on settlement and ground movement will be assigned.
The installation for the checkpoints such as ground settlement markers, building settlement
markers, tilting markers, piezometers, inclinometers, load cells, crack tell-tales, strain
gauges, etc. All monitoring records include graphical plots and tables should be kept on site
for inspection.
In case of contingent geotechnical situations, actions should follow that advised by the
Engineer.
Flood Prevention Measures - Station
Flood Control
The presence of water is anticipated during the work for Katong Park Station. The ground water is
expected to encounter during the excavation of station box owing to its more or less 30 m depth from
the ground level.

CONTRACT T316
Flooding in Working Area
It is very important to identify the causes of flooding inside the construction area in preparing for the
preventive measures to be adapted.
1) Permeable Soil
There is a very large variation in the permeability measure for the various soil materials during deep
excavation works and this reflects the difference in original rock type, weathering and fracturing and
difficulties in measuring the mass behaviour of the material.
2) Atmospheric Condition
Generally, Singapore is situated where monsoon rains occur. The country’s wet season falls during
the months of October to January.
The dry season is from February to early March. December accumulates most rainfall in a year. The
driest month is February. The table below shows the mean total rain days per month. It is calculated
by averaging the total number of rain days for each month for the 25 year period.
Mean Total Rain Days per Month
Month Mean Total Rain days

January 11.3
February 6.9
March 10.3
April 11.6
May 10.8
June 10.1
July 10.5
August 11.2
September 10.8
October 12.3
November 14.8
December 16.5
The highest 24-hour rainfall figures ever recorded was 512 mm (1978), 467 mm (1964) and 366 mm
(2006).
The flood water from raining will intrude the construction area by entering through the construction
opening of excavated area if not properly designed for flooding. It is important to know the weather
forecast for site preparation.
Water Intrusion & Flood Prevention Measures
Flood Prevention Measures – Station

CONTRACT T316
As a precautionary measure, sand bag barrier can be used to prevent the further spreading of a flood.
Certain opening of station is protected from flooding using sand bags or they can be used to reinforce
other flood protection structures.
From the ground level, diversion ditches, dikes

or other suitable means will be used to prevent
surface water or rainwater from entering and
accumulating in the excavation. Surface water
or rainwater will be rerouted to the nearest
water drainage. From the excavation site, sump
pits will be built to selected areas and water
control system will be installed i.e. submersible
sump pumps of appropriate capacity and other Figure 35: Sand Bag Placement
equipment to control the accumulated water and control the possibility of flood.
Operation for water control is controlled by a competent person to ensure proper operation. Also a
standby pump will be kept for emergency purposes.
General Site Precautions
The following measures will be known to every workforce on site:
1) “Emergency Exit” or arrow signs leading to assembly location should be visible. The signs should
be written in English, Korean, Malay, Chinese and Hindi languages.
2) Intercom system must be installed to be used during emergency to improve reaction time.
3) Proper lightings to be installed within the confined space of station.
4) The passageway should always be cleared from any obstruction on the way to exit.
5) Preparation of a lift for easy evacuation of workers by hoisting up.

CONTRACT T316
Protective and Emergency Equipment
1) Personal Protective Equipment (PPE)
a) Helmet mounted lights b) Flashlights, back light and c) Emergency whistles and
spare batteries radio
2) Emergency Equipment
Submersible pumps

CONTRACT T316
Emergency Plan
1) Emergency Plan
Supervisor/ Foreman in charge will initiate evacuation if flooding in station appears to be dangerous
or life threatening.
The following action would be taken by those on the affected area:
a) Raise the alarm in the station bottom and communicate to top signalman or safety/security
officer
b) Switch off all machinery and electrical equipment to prevent machine breakdown and
possible electrocution of workers
c) Start to evacuate from station bottom using access ladder or man cage on the escape ways
d) All persons must proceed to Assembly Point for head count.
2) Emergency Drills
Emergency Drill is necessary at least once in every three months. It is to inform, all of the work force,
the procedure to prevent flood from further intrusion and how to access on designated escape ways
in any flood occurrences. The drill should be in cooperation with Singapore Civil Defense Force
(SCDF).
3) Important Contact Numbers

During the commencement of the Station Works, it is important to gather several contact numbers of
key personnel involved in the project for ease of communication.

CONTRACT T316
Noise Enclosures and other Equivalent Noise Abatement Measures

Introduction
Management of noise pollution and vibration control will be given a high priority. Since the works are
in close proximity of occupied buildings, school zone and residential areas, the Contractor will provide
noise barriers to minimize any disturbance to the public and to adhere with statutory levels imposed
by the Regulations as specified by NEA and other requirement specified in General Specification
Appendix V.
The Contractor will also install real time noise and vibration monitoring devices on locations agreed
with the Engineer that may include portable noise devices.
Noise Enclosure & Hoardings
Prior to construction, hoardings including its support and footings will be erected to demarcate the
work areas and to secure the public from the works.
The hoardings will be constructed following the requirements of Site Hoarding in Appendix V of
Particular Specification.
The noise barrier will be constructed as per the proposed layout following the recommendation
stipulated in the EIA report (Appendix K). Particular attention would be given to protect existing
buildings, school residential buildings by providing noise enclosure.
The setting out will follow the line parallel to the site hoarding inside the site, keeping a distance of
500 m approximately from the site hoarding.
Noise Mitigation Measures
Noise mitigation measures at Katong Park Station are as follows:
Only sound-reduced machinery and equipment will be used on site.
Machinery and equipment deemed to be noisy will be enhanced acoustic enclosures as

directed by the Engineer.
The Contractor will mainly use power supplied by Power grid, a generator will only be used
when it’s absolutely necessary.
Pipe transporting bentonite will be shielded by acoustic insulation materials.
To break the rock, we will adopt controlled blasting method.
All equipment will be maintained to mint condition to minimize noise due to loose bolts or
parts.

CONTRACT T316
Noise Barrier Installation
Noise barriers are required to reduce the impact of noise generated during station construction to
acceptable level as required by National Environment Agency. This method includes the following
scope of works
Procedure
Item Scope of works
- The H-piles to support the noise barriers are set out every 2.0m,
center to center
1. Setting out - The setting out will follow the line parallel to the site hoarding
- Trial trenches are carried out to ensure that the underground utilities
and services in the areas are not affected
- The H-piles are placed on the ground embedded in a concrete

2. Installation of H-piles foundation to reinforce safety against overturning caused by wind,
etc. and strengthen maintenance of noise barrier
- Connection works contain welding jobs of horizontal & vertical

3. Connection details panels and clamping
- These must carry out following the work platform requirements
Drawings of Noise Barrier

CONTRACT T316
Noise Barrier Images

CONTRACT T316
Proposed Location of Noise Barrier
Noise barrier, when it is required, will be installed at the proposed work site at every stages of the
traffic diversion. See below images the proposed locations of noise barrier in red line color.

CONTRACT T316
Noise Barrier location during Stage 1A-Traffic Diversion
Noise Barrier location during during Stage 1B-Traffic Diversion

CONTRACT T316
Noise Barrier location during Stage 1C- Traffic Diversion

CONTRACT T316
Noise Barrier location during Stage 3 - Traffic Diversion
Noise Barrier location during Stage 4 - Traffic Diversion

CONTRACT T316
Plans and Proposals to adopt Labour-Efficient Construction Methods

Introduction
To ensure the labour-efficient construction methods for enhancing construction productivity in view
of the recent regulatory changes to curtail man-year entitlement quotas, the Contractor is proposing
to apply the following procedures below:
Use of more labour efficient construction methods
Item Descriptions
System forms will be used during the construction of the station.

The Tenderer will hire certified expert form & scaffolding installers
1) System Forms & from suppliers/fabricators. We will also order a factory cut and bent
Prefabricated Rebar
(prefabricated) rebar as much as possible to eliminate wastages
and long man-hour on site fabrication.
The workers and staff will be required to undergo regular onsite

training on how to increase their knowledge and efficiency in their
2) Training & Control
respective field of responsibility so that it would result a productive
and efficient output including the safety toolbox.
The Tenderer will award the deserving labors and staff of

recognition, promotion and incentives of their good performances
3) Recognition, Promotion &
Incentives in their respective trades to further encourage others to do the
same.
For all drainage structures and sewer manhole, we will use precast
4) Precast Concrete
concrete to expedite the installation time.
Multi-skilled labuors who can work for multi-jobs or are versatile in
5) Multi-skilled Labours work will be employed to reduce hiring many labours for different
trades required in the works.

CONTRACT T316
Use of Innovative Plant and Equipment during Construction
Item Descriptions Remarks
Where it is applicable or if the work so

dictates, the Tenderer will install steel
sheet piles using silent piler to reduce if
not eliminated the noise and the
vibration during pile driving.
1) Silent Piler
This machine does not use drop
hammer for driving piles but by pushing
the piles into the ground using its own
weight and already installed sheet piles.
It will be utilized for pipe jacking in

trenchless sewer pipe installation. It will
eliminate open cut excavation and cut
and cover procedures for sewer pipes
installation thereby greatly reducing the
2) Hydraulic Jack excavation volume and surplus
materials.
It is environmental friendly by reducing

noise, dust, construction vibration, and
other construction pollutions.
Use of boom and scissor lift instead of

traditional of scaffold for AMEP
(Architectural, Mechanical, Electrical &
3) Boom &
Scissors lift Plumbing system), installation of the
Steel Structural Elements at the
Proposed Station Entrances

CONTRACT T316
Other Innovative Methods of Construction for the Productivity Drive
Item Descriptions
- The Tenderer may consider widespread deployment and use of

interoperable technology applications, also called Building
Information Modeling (BIM) if needed
- How to use BIM for whole project duration

1) Introduction of BIM
i) Check for clashes between M&E services, structural provision
and architectural objects
ii) Produce M&E coordination drawings and concrete body plan
for construction purposes
iii) Simulate construction schedules and resource plan
- The Tenderer can collect productivity and other related date of

construction by using the Electronic Productivity Submission
2) Biometric System for System (ePSS)
manpower Date
Collection
- The Biometric System shall be able to account for the manpower
usage for the construction works including under the building works
The Tenderer will use tools like CCTV/Construction Camera to

3) CCTV/Construction conduct real time monitoring on site to study resource flow, schedule
Camera
and work process flow

CONTRACT T316
Construction Equipment to be deployed
General
The Contractor will deploy based on the approved Programmed of Works the following Principal
Plants and Equipment to site in advance prior to its implication or association in works as it may take
considerable time for bringing in such plants and equipment after the contract award. The list of the
Contractor’s Principal Plants and Equipment will be covered on this section.
Soil Excavation
Equipment
Below is the list of the proposed equipment for carrying out the excavation works.
Work
Item Description Quantity Images
Application
Hydraulic For deep

Excavator excavation of
Zaxis330LC Launch Shaft
1 (Telescopic (LS6) and 3~4 units
Clamshell) / GBME
CAT330 tons Receiving and
long arm Escape Shaft
For
standard/norm
Hydraulic al excavation
Excavator purposes and
CAT320 or will be
2 CAT330 optimized 4~6 units
standard arm using larger

excavation
buckets to
speed up the
excavation

CONTRACT T316
Work
Item Description Quantity Images
Application
For limited
area/space
excavation
purposes. Will
Hydraulic be brought
Excavator down to lower 8~10
3 CAT314 level to carry units
(compact size) out deeper

excavation
For limited
area/space
Hydraulic excavation
4 Excavator purposes. Can 4 units
CAT308 be optimized
with front soil
blade

CONTRACT T316
Diaphragm Wall
Trenching Equipment
Below is the proposed equipment for carrying out the deep trenching works of diaphragm wall.
Work
Item Description Quantity Remark
Application
For trench
Mechanical excavation of
1 3 units
Cable Grab Diaphragm
Wall
For Deep
Bauer Trench trench
Cutter (BC 40) excavation of 2 units
or hydrofraise Diaphragm
Wall

CONTRACT T316
Bored Pile
Boring Equipment
Below is the proposed equipment for carrying out the boring works of bored piles.
Work
Item Description Quantity Remark
Application
For drilling of
deep and
BG 40 Rotary
larger
1 Drilling Rig 1 unit
diameter
(Bauer)
holes bored
piles.

CONTRACT T316
Ground Improvement
Grouting Equipment
Below is the list of the proposed plant & equipment for carrying out the grouting works of ground
improvement.
Item Name Description Quantity Remark
Casagrande
C6
JET Weight: 12.7
GROUTING ton
1 5 Units
Hydraulic Dimension :
Crawler Drill
2.25 m x
7.71m x
2.77m
Soilmec
7T500J
Weight: 12.5
Ton
High Pressure Dimension:

2 2 Units
Grout Pump 2.44m x
2.59m x
6.06m
Power: 536
HP.

CONTRACT T316
Tecniwell
TW400
Weight: 12.5
High Pressure Ton

3 Dimension: 2 Units
Grout Pump
2.44m x
2.59m x
6.06m
Power: 350HP
Automatic
Grout Mixer:
3 Sets
Tecniwell TM-
20
Cement grout
4
Mixer
MATX TM-20 3 Sets
FAV1.0 m3
1 Set
Turbo Mixer
Dimension:
1.9mx4.5m
5 Water Silo 2 Units
Capacity:10.0
m3

CONTRACT T316
Dimension:
1.52m x
1.52m x
6 Water Tank 3.05m 4 Units
Capacity: 6.0
m3
Electronic DAT
7 5 Units
Data Logger Jet4000AME
Dimension:
Double Tube 100
8 Ø88.9 mmm x
System Rods Lengths
3.0m/ Length
Type Double
Double Tube Tube system
9 7 Sets
Jet Monitor with two
monitor
Type:
Air
10 390CFM 4 Units
Compressor
/100PSI

CONTRACT T316
11 Generator Type: 125kVA 4 Units
Koken grout Type: M-10 2 Units

12
Pump M25 2 Units
Cement Grout Techniwell

13 4 Units
Pump Type: TW-100

CONTRACT T316

CONTRACT T316
EPB TBM Bored Tunnels
Introduction
This chapter shall briefly outline the procedure of bored tunnel construction via Shield Tunnel Boring
Machine (EPB TBM) for the successful completion of Tunnels for Contract T316.
All drawings and sketches enclosed in this method statement are concepts only and may therefore
be subject to changes or complete modifications prior to actual performance of work or as the work
progresses.
These changes or modifications will be in accordance with the design changes by Authority, actual
site conditions and other driving factors not foreseeable at the Tender stage.
Tunnel Site Location
Figure 36: Tunnel Layout for Contract T316
TBM Performance Concept
The Contractor will launch Two (2) EPB TBM from Launch Shaft at Changi Airport Terminal 5 (T5)
and be driven to construct the twin-bored tunnels toward Terminal 2 (T2). The tunnels run through
the proposed underground infrastructures building of Contract T316 outside Changi Airport Perimeter
and will run inside Changi Airport perimeter under Existing Fire Station 2, Taxiway lanes, existing
runway 2 before reaching the Terminal 2 (T2).
The Contractor will drive both TBM at the same time to the tunnel alignment outside the Changi
Airport Perimeter. When entering the Changi Airport perimeter, the Contractor will operate the TBMs
one at a time when crossing under taxiway lanes and Runway. During and before operation of TBMs,

CONTRACT T316
the Contractor will coordinate properly to LTA’s Engineer and other concern personnel.
Tunnel Organization & Responsibilities
Organization Chart
Please refer to Package 4 A.1. Overall Organization Chart.
Responsibilities
Tunnel Manager
● Responsible for overall Tunnelling works

● Coordination with Authority and Authority’s representatives
● Approve and advice Compressed Air Works, TBM Operational Parameters, etc.
Senior Tunnel Engineer
● Oversee Tunnelling site operations

● Manage equipment, material, manpower and ensure work is on schedule
● Check the working situation in accordance with the method statement
Tunnel Engineers
● Responsible for day-to-day operations of tunnelling works with guidance from the
senior tunnel engineers
● Prepare TBM Operation Instruction sheet
● Coordinate between TBM, Surface, Backfill Plant staffs and determine any current and
potential problems
● Observe ring condition, supports, and TBM coordinates during TBM Launch & Initial
Drive with respect to tunnel eye opening
● Record TBM progress and encountered soil geology
● Compile all shift reports, ring building records, and necessary documents for tunneling
Tunnel Foreman
● Operate the TBM within the operation parameters set out in the TBM Operational
Instruction Sheet
● Respond to all instrumentation and control warning / error and alert engineers,
mechanics and electricians as necessary
● Ensure that the respective components of the TBM are locked off during maintenance
● Approved erector operator, responsible for ring build quality and safety of ring build
team
● Arrange plant maintenance with the aim to minimize disruptions to tunneling

CONTRACT T316
operations
● Ensure sufficient spare parts, lubricants, etc. for all plants on site
● Organize sufficient stock of required components for agents such as foam and polymer
etc.
Tunnel E&M Manager
● Check and supervise all plant maintenance as well as plant maintenance records
● Review of TBMs, Backfill Plant, Locomotive and Rolling Stock, etc. breakdowns &
downtimes and find ways to minimize time loss
● In charge for monitoring inventories of the required spare parts to be maintained on
site (e.g. TBM spare parts, Locomotive and Rolling Stock equipment spares, etc.)

CONTRACT T316
Geological Profile
General
The ground of Contract T316 comprises of reclaimed land followed by Kallang Formation and Old
alluvium based from the existing geological information and available ground investigation records
from GIBR report.
Site Topography
The topography of the Changi Airport is relatively flat ranging between 2.1m and 6.7m Singapore
Height Datum (SHD), but generally the average elevation is of approximately 4m SHD
Anticipated Ground Conditions
For ground works including ERSS, foundation and excavation works, and bored tunneling, a variance
of +/-3m from the interpreted geological profiles, as shown on the Geological Profile Drawings
described in Section Error! Reference source not found. Error! Reference source not found. ab
ove, shall be considered as foreseeable ground conditions. Any variations from the baselined
geological profiles shall only be justified by boreholes.

CONTRACT T316
Tunnel Work Flow chart
Fabrication and Delivery of

Shield TBM (2Nos.)
Construction of Launching Erection of Back-up Facilities
Shaft above ground
(by T316 Contractor)
Installation of TBM Cradle

Preparation of Initial Drive
and Reaction Frame
Shield TBM Assembly
Erection of Temporary
Initial Drive
Segments
Dismantling of Temporary
Segments Cradle and
Reaction Frame
Preparation of Main Drive

Installation of
Rails, Cables & Pipes
Main Drive
Dismantling in Shield TBM Dismantling of Back-up

Tunnel Facilities above ground
Construction of 1st Stage

Track Bed

CONTRACT T316
Site Establishment
Site Utilization Plan
The launch shaft area is located at Terminal 5 (T5) Development. The Contractor will do the ground
improvement and utilize the launch shaft accordingly following the Authority’s drawings. The site
utilization plan is as shown in figure below.
Your text here Crane

2
Gantry Capacity
n
(40 to
Figure 37: Site Utilization Plan
Back-up Facilities
The main worksite and staging area for the tunnelling back-up facilities on the ground will be located
on work site. The Contractor will utilized the site to set-up equipment/machineries, plants, and staging
areas for the tunnelling works as hereunder described as follows.
● Backfill Plant
● RC Segment Storage/ stock yard
● Gantry Crane
● Mechanical & Electrical Workshops, Material Storage, etc.
The Contractor will do, prior to mobilization and installation of support facilities for tunnelling works,
all preparatory works, such as clearing and levelling, temporary fencing, lighting, traffic diversion,
relocation of utilities, construction of temporary shoring and decking, etc.

CONTRACT T316
Upon completion of all site preparatory works, equipment/machineries and plants, the Contractor
shall mobilize and assemble, strategically place in accordance to the launching shaft location.
Compressed Air Facilities
General
Clean, dry quality compressed air supply is required when operators are in the man-lock chamber of
the TBM.
The high pressure compressed air ranging is conveyed into the deep tunnels through the main pipes
before the pressure is reduced to a lower pressure at the point of use. This is to ensure constancy
of air flow overcoming friction losses in long distance pipes.
Setting up
Compliance with the contract specification, compressed air plant will be set up and commissioned
on the surface before TBM launch. The design calculation of compressed air plant required capacity,
plant and equipment lay out, methodology of compressed air works and safe work procedure
pertaining compressed air works will be outlined in method statement for compressed air works. The
Engineer approval of compressed air works method statement will be sought before TBM initial drive.
Compressed air plant consists of two electrical compressors, two dryers, one air receiver and series
of filters and monitoring units. Each tunnel will be supplied with individual compressor and dryer.
Stand by diesel generator will be provided as a backup air supply should the substation power failure
or malfunctioning of air compressors.

CONTRACT T316
Electric-driven air compressor with its Air Dryers and Filters for each TBM shall be operational at all
time. The pipe directed to the TBM shall consist of 4" nominal diameter and internally / externally
galvanized pipe.
Two sets of individual pipe system shall run in parallel connecting from the two supply valves of the
compressed dry air system, one being the main pipe system and the other being the stand-by pipe
system. Piping at TBM end shall be fitted with individual shut-down valves. The two supply valves at
compressed dry air end shall be turned on at all times to allow both piping systems to be constantly
filled-up with air.
For the shut-down valves at TBM end, main shut-down shall be normally open and standby shut-
down shall be normally closed. In the event of air leakage of the main pipe system, the operators at
the TBM shall turn on the valve of the stand-by pipe system that has an immediate supply of
compressed air.
The main supply valve at the compressed dry air can be turned off and leakage in main pipe system
to be rectified.
Commissioning
During commissioning and operations of the installed Compressed Air Facility, the following are to
be noted.
The Air Dryers & Filters cleanse and purify the compressed air by means of a series of air cooling,
condensate separation and filtration.
The moisture, oil-mist and particles are reduced to a level lower than the general atmospheric air
intake by the air compressor.
Pressure Dew Point: 3 degC @ 7 bar
Particles removal down to less than 0.01 micron
Oil-mist removal down to less than 0.003 mg/m3
The compressed dry air comprises the following safety and alert features;
Air Pressure Low Indicator I Alert
Air Temperature High Indicator I Alert
Air Dryness Dew-Point Indicator
Filters Quality Indicator
Functionality & Safety Check (Daily);

CONTRACT T316
All Air Compressors functional test shall be performed daily
Start-up air compressor
Check for any fault alarm shown in air compressor control panel
Confirm air compressor is able to build up to 8 bars pressure
Shut-down air receiver tank discharge valve
Confirm air pressure is able to maintain at 7 bars pressure
Shut-down discharge valve at TBM end, turn-on tank discharge valve
Confirm air pressure is able to maintain at minimum 6 bars pressure
Maintenance and Inspection (Quarterly);
Service of Air Compressors & its ancillary equipment is according to manufacturer’s

requirements
Inspection of all fault/maintenance alarms includes air dryness and filter quality
Provision of Associated Foundation
Platform area to where lifting equipment will be positioned or erecting the gantry will be arranged
earlier prior to bringing them to sites. Pad foundation platform made up of crushed aggregate will be
laid according to the design level. In most cases, the platform does not need to be placed under a
mobile crane unless the crane is operating on poor soil. To avoid settlement under the crane and
maintain levelness during operation, it is a good practice to place a crushed aggregate as a platform
foundation under the crane. Crushed aggregate will be constructed in the soil that is suspected to
subsidence where the ground conditions are very poor and bearing power of the soil is so low.
Method of construction of platform foundation:
Dug out the whole area to the specified depth and 30 cm more wide than the area to be
covered.
Compact the final formational level and sprinkle over with water.
Set up formworks if requires
Place the crushed aggregate uniformly and to the required thickness.
Final leveling

CONTRACT T316
Ground Improvement (Tunnel Alignment)
In accordance with the information given in the ITT, jet grouting will be proposed for ground
improvement. The Contractor may carry out actual soil investigation to determine other type of
ground improvement that can be applied during site execution.
Details for ground improvement method can be referred to Section 6 Ground Improvement. Below
images presents the proposed location that requires ground improvement for tunnel alignment. Exact
location will be identified during the actual survey on site.
Image Ground Improvement for Cross Passages 1, 2, 3, and 4
(Identify type of Ground Improvement)
Figure 38: Proposed Ground Improvement for Tunneling Work

CONTRACT T316
Launching Shaft
Introduction
Where the ground conditions are not favourable for tunnelling works, the Contractor will adopt ground
treatment to prevent settlement and uncontrolled water inflow during initial drive of TBM at the
launching shaft entrance. Please refer to the Figure below for reference; this is subject to change as
per the final design.
Figure 39: Launching Shaft and Thrust Block for TBM
Soil improvement at the entrance is the most important consideration at the initial stage of shield
tunnel construction. Grouting will be applied as a means of soil improvement at the tunnel launching
shaft prior to shaft boring to ensure ground stability. This process will prevent collapse of the tunnel
eye, hold the TBM weight wherein tilting is controlled and prevent ground water in-flow into the shaft
which will later cause serious ground settlements upon commencement of initial TBM operation at
the launching shaft.
TBMs Assembly
TBMs Lifting Arrangement
Introduction
Considering the size of the tunnel boring machines (TBM), its assembly often requires a multitude of
cranes. However equipment selection has much more to do with the jobsite itself than the equipment.
Judging on weight alone, even the very largest of TBM components is well within the capabilities of
heavy lifting cranes found throughout the world. The real complexity comes into play when logistics
is considered. TBMs are often assembled on cramped jobsites, in urban conditions with overhead

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lines, and amidst components staged in much of the available space.
Determining the proper crane type and assembly scheme is not always easy in such situations.
Whether the TBM is assembled for the first time on-site or initially put together in an assembly shop,
extensive pre-planning and collaboration is needed before these complex machines are ready for
work.
Figure 40: TBM Assembly
Handling heavy loads of machine parts safety requirements and/or measures
Where the weight, size or shape of a TBM prevents them from being moved by hand, the parts shall
be either
Fitted with attachments for lifting gear or so designed that it is possible to fit attachments
for lifting gear
or so shaped that standard lifting gear can easily be attached
Suitable equipment shall be provided for transportation and lifting of such parts which require regular
replacement e.g. cutter disc.
Space for Lifting Arrangement
Space available should be considered which will lead to the decision of what type of crane to be
employed at the assembly area and the weight of the components to be handled. The shaft location
where the TBM is to be placed is located in urban area where space is limited for movement during
lifting and handling the TBM. In terms of size and mobility within a limited space, there are clear
differences in the types of cranes to be used.
Lifting Equipment
Mobile Cranes
Mobile cranes will be mainly used in erecting the gantry cranes at the launching shaft. For the

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assembly of TBM machine, a dedicated 700 tons mobile crane will be used at launching shaft for
lifting and handling.
Figure 41: Gantry crane lifting muck container (Right) & Mobile crane lifting cutter head (Left)
Gantry Crane
Two (2) 40 tons gantry cranes will be installed for tunnelling works perpendicular to the alignment of
two bored tunnels. The gantry crane will be used mainly for EPB TBM logistic supply, muck haulage,
segment supply to TBM and other lifting works direct to tunnel access. Maximum to be carried out
by the crane shall be within their safe working load. If incase failure arises during the work that may
probably cause to delay the site works, mobile crane with similar capacity will be mobilized
immediately in order not to disrupt the tunnel progress.
Below tables shows the technical data for gantry cranes.
No. Technical Data Gantry Crane

1 Safe Working Load 40 tons
2 Weight of crane 45 tons (approx.)
3 Working Span 24.8 m (main)
4 Height of lifting (on ground level) 12 m
5 Power Voltage 415 AC/ 50 Hz
6 Hoisting Speed 0~30 m/min, 190 kW

7 Long travel speed 0~30 m/min, 4x2.5 kW
8 Traversing speed 0~30 m/min, 2x2.2 kW
Testing and commissioning of these gantry cranes with PE certification will be conducted on site
prior to use. The PE certificate will be submitted to Engineer for approval. The crane is kept within
the work site and keen monitoring will be carried out during operation.
TBM Assembly Sequence
Contractor will prepare the base foundation platform prior to assembling the cradle. Assembly of the
Tunnel Boring Machine (TBM) will be done on TBM cradles constructed at the launching shaft. Each

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part of TBM bodies will be lowered by mobile cranes and assembled in position on the TBM platform.
The full TBM assembled body on the launching shaft will be fixed to the reaction frame. Back-up
facilities will also be delivered in sections and erected on the ground. It shall be then later connected
with the TBM via series of pipes upon commencement of work until completion.
1st Step: Positioning Lower Front Shield 2nd Step: Positioning Lower Intermediate
3rd Step: Positioning Drive Unit 4nh Step: Positioning Upper Front Shield
5th Step: Assembling Erector & Man Lock 6th Step: Positioning Upper Intermediate Shield

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7th Step: Positioning Cutter Head 8th Step: Positioning Lower Rear Shield
9th Step: Positioning Erector Beam 10th Step: Positioning Erector
11th Step: Positioning Screw Conveyor 12th Step: Positioning Upper Rear Shield
13th Step: Positioning Reaction Frame

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Bored Tunneling Works
Preparation of Initial Drive
Installation of the Entrance Packing
The function of the entrance packing is to prevent ground water and loose soil from flowing through
the gap between the shaft wall and the TBM skin. It also serves as a seal of the tunnel portal
preventing injection material seepage during the break-in on the portal. Components of entrance
packing are entrance ring, rubber lip seals and floppers. Entrance ring will be constructed as soon
as the base slab is permitted to be loaded or has attained the required strength.
After the construction of the Entrance Ring, portal frame will be constructed. This tunnel Portal Frame
or Breakout Wall is a reinforced concrete structure that will hold the entrance packing. This will aid
in stabilizing the force or the torque induced by the TBM as it enters the tunnel drive. After the casting
of the tunnel portal frame, double rubber lip seals will be installed and floppers will be attached in the
entrance ring to prevent injection material leakage. These floppers will tend to bend together with the
rubber seals as the TBM enters the tunnel portal.
Installation of the TBM Cradle
Assembly of the Tunnel Boring Machine (TBM) will be done on TBM cradles constructed at the
launching shaft. The TBM cradle consists of H-beams, stiffener plates, and solid round bars
connected by bolts and fillet welds. It will be installed on top of the concrete base slab. Welding
activities shall be minimized in a confined space; thus the main connection for this cradle will be by
bolts. Also, the cradle shall have an upward slope to maintain the TBM level required as the TBM
tips down when entering the tunnel.
Figure 42: Typical TBM Cradle
The Contractor will make the cradle to withstand the weight of the TBM considering its thrust force

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during initial excavation. Its stability is important as the assembling of TBM and alignment levelling
is to be done on the platform. Initially, the cradle will be set at flat level relative to design tunnel
alignment and raised 30 mm from design tunnel alignment at face of tunnel entrance ring in order to
compensate for anticipated TBM nose dive during TBM break out. The TBM behavior will be
monitored during launching to make sure that the TBM level is within above the design tunnel level
but within the allowable tolerance until the TBM body is fully enter into ground treatment area.
Thrust/Reaction Frame
Thrust frames are prefabricated off-site as per approved design drawings. The position of these
frames are at the surface bottom area to suit the temporary ring arrangement on TBM cradle. The
thrust frames will be designed to resist for maximum expected thrust calculated for TBM launch and
initial drive and to transfer the thrust force applied from the TBM to shaft base slab. The thrust frame
consist of a vertical steel frame (which receive thrust force form TBM shield jacks via the blind rings)
and raked steel column which transfer thrust forces into shaft base slab.
The thrust frame will also be anchored to the shaft base slab to resist the tendency for the frame to
lift. It will be installed after TBM body have been assembled on the cradle and positioned at the face
of tunnel eye seal with removal of extension cradle. If required, the frame base are checked and
shimmed to the correct level. The reaction frame must be positioned and setup on the foundation
once the main shield components are installed on the cradle.
The reaction frame shall be assembled in accordance with the following sequence
Prepare all anchor foundation connections
Check vertical and horizontal position with surveyors and adjust as required
Infill gaps with non-shrink grout as required
The vertical faces of back-truss shall be perpendicular to the centre line of the tunnel in both

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horizontal and vertical planes. The gaps between the temporary segment links and the back-truss
will be sealed with mortar/steel plate to have a uniform distribution of jacking force transferred from
segments links to back-truss.
Prior to thrust frame installation, tunnel surveyor will set out the center line and base line chainage
of the thrust frame at the shaft bottom area. The verticality of thrust frame will be set perpendicularly
to the cradle. Shim plates and timber wedges will be prepared prior to installation of temporary rings.
As built survey of the thrust frame leading edge will be taken to check for any shim plate is needed
prior to installation of 1st temporary ring. Before the TBM push against the thrust frame, the design
PE shall check and issue a letter of acceptance for loading.
The frame is installed after the TBM has been lowered and positioned at shaft bottom. The screw
conveyor protrudes through the frame during installation as shown in the drawing below. Each
component members of frames will be connected on the base slab, the components lowered using
the 40t gantry crane. Proper working platform will be provided to allow for safe work environment
while the corner pieces and upper beams are connected. Every connection bolts are tightened to
required tension as per approved drawings.
Initial Driving
General
Initial drive excavation procedure will follow the TBM operational parameter for the first 140 m for
each of the tunnel drives. However, the TBM parameters may change depending on the actual
ground condition.
TBM Advance
Tunnel face will be supported by applying a positive pressure using air pressure in the excavation
chamber of the TBM at all times. The air pressure with the spoils inside the excavation chamber will
continuously maintain to allow the excavated ground to be conveyed away from the face along belt
conveyor via screw conveyor to the muck skips on the surface. The screw conveyor, belt conveyor
and the screw conveyor gate will be adjusted according to the ground condition and the TBM advance
rate. The face pressures have been analyzed for drained and undrained stability conditions. The
recommended face pressures are higher than the design face pressures by 20 kPa for safety.
However, the face pressure will actually be used and will be agreed and approved by QP(S) and
Engineer before prior to each shift. The Tunnel Manager will review prior to each shift together with
the Senior Tunnel Engineers the latest settlement monitoring readings, the TBM operation
parameters and the actual ground conditions encountered at the face during the previous shift.
The proposed face pressures shall be submitted to QP(S) and Engineer prior to each shift. It is
imperative that the face pressures used during tunneling are approved and agreed by QP (D), QP(S)
and Engineer before implementation.

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The face pressures and the required grouting pressures will then be instructed to the TBM Operator
and the shift Engineer before commencement of the shift. Any deviations from the design face
pressures will have to be approved by the QP(S) and Engineer. The fluctuations in the face pressure
at the face will be kept within +/- 0.2 bar as far as possible. The face pressure will be monitored and
adjusted as necessary upon approval by the Tunnel Manager from the monitoring computer installed
in the site office with the acceptance of QP (S) and the Engineer.
Temporary Segment handling and Installation
Temporary segment rings will be individually assembled at the top of the platform as the TBM
advances. Each segment rings installed shall be supported with wedges in order to maintain the
circular shape for the uniform distribution of jacking force. The TBM will then continue to move
forward with the installation of the segments until the segment ring reaches the entrance of the shaft.
Most importantly, segment rings shall be tied together by wire ropes attached to the platform to
maintain their original position and shape during jacking thus preventing twist or rolling while the TBM
advances through the shaft. Selection of key segment position will be done by Tunnel Engineer who
is responsible to ensure that erected segment shall be aligned with TBM alignment and have enough
clearance between segment curves and TBM tail skin.
An Operation for Instruction will be prepared at the each shift and the sheet is approved by Tunnel
Manager. The ring erection and TBM steering are included in the TBM Operation instruction Sheet.
The Instruction sheet is issued to the TBM Operator to follow and copies are distributed to the Tunnel
Supervisor and Foreman. As-built ring data and TBM alignment will be reviewed constantly
throughout the shift by the Tunnel Engineer who may change key position according to actual TBM
alignment.
Figure 43: Temporary Ring Arrangement at TBM Launch Shaft

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Main Driving
Sequence
Since this stage consist of many activities, the sequence and program is very important. The steps
are shown below.
Factors to Consider in Sequence
The pipe has to be emptied prior to dismantling
All the hydraulic hoses & electric wires used for initial excavation are to be dismantled
Reaction Frame, TBM platform & temp segments shall be dismantled
Re-arrange the back-up facilities
Reinstall the working platform & install the rails for main operation
Reinstall all electric wires, pipeline for backfilling, air duct and hydraulic hose for main
excavation

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Main Drive
After the initial drive, preparation for the main excavation must be completed, then main driving
commences. Below flow chart shows the Sequence for the Main Drive work:
Important Factors to Consider in Main Drive
Monitor the excavated volume very closely. If over excavation has occurred, the excavation needs
more backfill grouting or in some cases need chemical grouting. Survey checks must be accurate to
adjust and control the alignment.
Effective coordination is also needed to achieve the best alignment possible with the original.
Confirmation has to be made with the system of operation when starting the main excavation as if
the alignment of TBM is deviating from the originally required position; it needs to be brought back
to the original position.
When starting the main excavation, ensure and confirm that TBM is in the correct alignment of TBM
as per design.
The productivity and quality during the main excavation has to be improved than the initial excavation,
using the data from the initial drive.
Accurate survey checks and effective coordination must be attained in order to achieve the correct
alignment possible. Data of the initial drive will be recorded. Main drive must attain higher productivity
and quality compared to the initial drive.

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Assumption/Derivation during Main Excavation
During the tunnelling process, if possible, it is necessary to visually inspect the cutter face. However,
it is not practical for the reason that the cutter face will be covered by muck. In order to locate the
obstructions, cutter wear, etc., identification method is needed which can only be developed using
the data from the initial and previous excavation period. This can be done by monitoring closely the
difference in excavation volume, earth pressure, sound, etc. The table below shows the identification
method to be developed with a more effective manner from the initial excavation data.
Problem Identification Method Prevention / Solution to Overcome
Increment in Torque Control Face Pressure

Ground Settlement
Increment in excavation volume Pass the location without intervention
Soil/ backfill grout Allowing more injection of chemical

Increment in torque
stuck/bonded on material to improve fluidity
Discharge volume will reduce
chamber If serious, has to be manually cleaned
Damage cutter Increment in Thrust force/ driving

Change the roller bit/ cutter wheel
wheel/ roller bit force/ propulsion than normal.
Manually remove by hacking...etc.

Increment in torque
Obstructions (With Airlock or soil improvement if
Change in sound
necessary)
Anticipated Cycle Time for Initial Drive and Main Drive
Estimation for the productivity (shown below) is based on soil condition (GIBR) and subject to
changes according to final geology encountered on site.
Item Initial Main Remark

Excavation (min/Ring) 340 142
Segment Installation (min/Ring) 175 83
Preparation for pre/post excavation (min/Ring) 30 15
Maintenance (min/Ring) 120 60 Including meal time
One Ring Cycle Time (min/Ring) 665 300
Ring 1.8 4.0
Daily 20hr/day
M 2.5 5.6
Ring 45.0 100.0
Month 25days/month
M 63.0 140.0 Considering C.H.I.
In Schedule M/mont 60 140

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Measuring
Monitoring and Reconciling of Excavated Material
Controlling of the volume of material excavated will be performed during tunneling by calculating an
estimated muck discharge rate in real time, which will then be checked during excavation against the
theoretical muck discharge rate.
In order to determine the estimated muck discharge rate, the bulk density and moisture content of
the expected ground conditions will be identified for each type of ground conditions expected at
tunnel horizon. This data is available from the results of the soil investigation works for each soil type
and will be selected by the Tunnel Engineer or Senior Tunnel Engineer and approved by the Tunnel
Manager prior to start of each shift depending on the anticipated ground conditions derived from the
longitudinal section of the ring layout drawings.
The estimated muck discharge rate will be derived from the bulking factor of the prevailing ground
conditions which shall be heaped on the belt conveyor. At the end of the belt conveyor is an automatic
weigh bridge already incorporated with the TBM, which works on the principal of X-Ray system.
Guidance System
To measure the location and driving direction of the TBM, at least two defined points of the TBM,
together with pitch and roll, must
be measured in three-
dimensional space. These two
points are the locations of two
prisms installed in the forward
section of the TBM. Their exact
location relative to the TBM axis
and local TBM coordinate system must be determined only at TBM set-up.
Additionally, because the TBM may roll and pitch, the TBM coordinate system is usually not parallel
to the global coordinate system. Therefore, roll and pitch of the TBM must be measured accurately
and such measurement is performed electronically by two-axis inclinometer mounted inside the TBM.
The two prisms inside the TBM are automatically measured by a motorized theodolite whose
standpoint and orientation have been previously defined. A new theodolite standpoint can easily be
determined by standard surveying methods as an additional function in the system. However, since
the horizontal angle measurement system of a theodolite has no defined reference point, the
theodolite must be orientated during installation by manually measuring with the theodolite to a
reference point, whose co-ordinates have been determined previously.
This measurement information is inserted into the system computer by the survey staff. Subsequently,
the global co-ordinates of the two primary points on the TBM may now be established by measuring

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the slope distance and horizontal and vertical angles from the oriented theodolite.
Since the location of the prisms in the TBM co-ordinate system was established at TBM set-up, and
the roll and pitch of the TBM are known at all times, any point of the TBM (e.g. the center of the cutter
head) can be calculated in global three dimensional spaces.
The design centerline is also known in the global co-ordinate system and has been previously
entered into the system computer. Therefore, horizontal and vertical deviation of the TBM from the
centerline, together with TBM orientation, can be easily calculated and presented graphically to the
TBM pilot. If desired, a projected path can also be calculated and displayed to show the optimum
path back to the design centerline, considering parameters such as minimum turning radius, or,
related to the geometry of pre-cast liner elements.
The importance of the remote prism cannot be overstated. Not only does the remote prism enable
the orientation of the theodolite, but it also allows automatic on-line detection of potential errors
caused by any movement of the theodolite standpoint.
Because the theodolite is usually mounted on the possibly unstable wall of the just-drilled tunnel,
about 25 to 300 m behind the TBM, it has a high potential for movement. Such movement, if
undetected, can have a disastrous effect on the accuracy of mining.
Consequently, the TBM Guidance System periodically measures the remote prism to check the
stability of the theodolite standpoint and notifies the pilot if movement has occurred. The interval of
these reference measurements is fully dictated by the user through the use of password-protected
parameter menus.
Trouble in TBM Drive
Uncertainty of underground formation’s properties ahead of the TBM face causes trouble when
tunneling and it may induce unexpected displacement of ground.
According to the report regarding ‘troubles in TBM tunnel drive’, troubles arise from geological and
mechanical factors. Main troubles are due to geological condition at the working face. And such
trouble sometimes requires number of days of construction suspension, which is implying that proper
preventive countermeasures shall be necessary in the design stage, in order to minimize any
geological constraints.
Optimal counter-measures depending on the characteristics of troubles needs to be established to

cope with the troubles in advance. Such troubles are still remained unsolved in advance. However,
immediate responding measures to secure troubles such as collapse in front of TBM face shall be
taken into considerations.
Geological troubles derived from falling debris of cracked rocks that collapsed, abrupt water
generation by high pressure, extruded ground from the soft ground and insufficient bearing capacity

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of soil. And it can only be detected in front of the TBM face attached with radar system or visual
inspection and also by means of probing and grouting at the tunnel face will be done if necessary.
EPB TBM at each station
General
Face pressure will be maintained whilst permanent connections of the TBM shields are made to the
steel liners in the sleeves.
A positional survey of the TBM is to be made at a distance of some 30 – 50 meters from the sleeve.
The docking procedure is completed by the installation of a welded seal between the skins of the
TBM and the steel liners in the sleeves and the subsequent infilling of the annular space between
the TBM skins and the steel liners back to the last pre-cast concrete segment ring with concrete.
Launching at T23 Station
The two EPB TBMs are to be driven into the D-walls of the twin mainline bored tunnels at the east
end of station T23 of contract T303 Tanjong Rhu cut and cover tunnel to the west end of TE24 Katong
Park Station. The target for TBM at concrete reinforcement for D-walls will be GFRP.
An in-line tunnel sump located at the Changi bound bored tunnel will be constructed to satisfy tunnel
discharge requirements. Ground improvement between Woodland Bound chainage CH43+492 to
CH43+516 will be provided for the protection of the buildings adjacent to bore tunneling works.
Docking at T24 Station
The Contractor will design and construct GFRP at two (2) ends (D-wall panels) as soft eyes of Katong
Park Station for the ease of the EPB TBM for tunneling through.
Temporary rings for tunneling through the station will also be design and construct by the Contractor
which should be sufficient against all temporary and permanent load and load combination cases
arising from the Contractor’s construction activities during excavation of Katong Park Station.
A detailed method statement for the removal of the temporary rings at the Katong Park stations shall
be prepared by the Contractor for Engineer’s approval to maintain the logistic in tunnels during station
excavation before construction.
Docking at TE25 station
The twin mainline bored tunnels will be driven continuously from Katong Park Station to the west end
of Amber Station.
Ground improvement along the alignment as shown in the Drawings will be completed prior to
tunneling works.
Prior to driving through the west end of TE25 Amber Station, the Contractor will coordinate earlier to

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the contractor of TE25 station. Diaphragm wall at west end of TE25 amber Station which is the soft
eye for tunnel drive through will be constructed by the Contractor prior to tunneling.
Table 7: Location and Dimension of ground Improvement
Chainage of Ground Improvement Structures of Concern
43+492.3458 to 43+515.7293 SM21
44+668.3884 to 44+710.7926 SM109 & SM 110
45+136.5537 to 45+192.114 SM 153 to SM 156
45+273.0793 to grout block SM256 & SM 257
Cutter-Head Interventions (CHI)
General
The main purpose of intervention is to check the cutter-head and change cutting tools regularly to
prevent detrimental wear and tear to the cutter-head which may require lengthy period of repair or
may resort to a total cutter-head replacement which is very costly. Accordingly, the repair or
replacement of cutter-head will cause major cost impact and delay to the progress and completion
of the Project tools.
Generally, the planned intervention to inspect the cutting tools and other exposed surface shall not
be greater than 200 m unless otherwise accepted by the Engineer as per particular specifications.
In areas where intervention is to be avoided, intervention shall be made within 20 m before the face
reaches any of these areas. An intervention shall also be made when the head reaches the location
of the cross passage or prior to tunneling beneath specific structures.
If the TBM has to stop in a permeable area and maintenance of the cutter head is required, the area
in front of the TBM may require ground improvement to sufficiently reduce permeability to allow open
face working.
Alternatively inspection and maintenance stops can be planned in advance so that the TBM stops
occur in naturally non permeable zones or in areas previously grouted to prevent groundwater inflow
and reduce settlement.
The reason for such planned stops is to allow access to the cutter head in open, free air conditions
rather than in compressed air which is extremely difficult and the working conditions is hazardous.
It is proposed that for cutter head intervention, probing ahead should be done from the TBM to verify
the ground/ seepage conditions. In case the permeability of rock is high, compressed air or pre-
grouting is recommended to prevent groundwater ingress, water drawdown and reduce ground

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settlement. Compressed air is used in intervention for the purpose of preventing the ingress of water
into the excavation chamber which is comparable to grouting sealing effect.
If the condition is dry, the cutter head intervention may be carried out under free air with monitoring
of piezometers/ water standpipes nearby.
Here are the steps and considerations for cutter intervention.
Pre-intervention assessment wherein relative risks involved are assessed either to conduct
the intervention or to delay the intervention
Intervention Preparation works required if it is decided to conduct an intervention
Intervention Checks required while conducting the intervention to ensure safe working
conditions
Proposed Cutter-head Intervention Locations
Launch Shaft (TE23) to TE24 Katong Park Station up to TE25 Amber Station
The twin bored tunnel from Launch Shaft up to brink of Katong Park Station is approximately 650 m
upon which ground improvement will be carried out.
The consolidation of soil, after application of ground improvement, will produce a homogeneous
improved zone with at least 450 kPa undrained shear strength.
The Contractor proposes the first (1st) intervention to be made after completing the initial drive from
the entrance / exit portal of Launch Shaft towards the Katong Park Station at approximately Sta.
43+500 for Woodlands bound tunnel and Sta. 43+471.6 for Changi bound tunnel.
The second (2nd) intervention is proposed after completing the succeeding 100m bored tunnel length
from the first intervention station towards Katong Park Station approximately at Sta. 43+847 base on
Changi bound tunnel.
The third (3rd) intervention is proposed to follow after completing 608 m bored tunnel length from the
second intervention station towards Katong Park Station at Sta. 44+455.
The fourth (4th) intervention is proposed to follow after completing 228 m bored tunnel length from
the third intervention station towards Katong Park Station at Sta. 44+683.
The fifth (5th) intervention is proposed to follow after completing 230 m bored tunnel length from the
third intervention station towards Katong Park Station at Sta. 44+913.
The sixth (6th) intervention is proposed to follow after completing 238 m bored tunnel length from the
third intervention station towards Katong Park Station at Sta. 45+151.
The cutter-head will be checked and all worn out cutting tools will be replaced prior to proceeding

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the tunnel boring works at every intervention.
To the last intervention, rigid check will be thoroughly taken up for cutter-head prior to proceeding
the tunneling works in the marine clay which will be longer than the Standard. The cutter-head will
be checked and all worn out cutting tools will be replaced prior to proceeding the tunnel boring works
until completed up to the TE25 knock out wall.
1st
2nd
1st
3rd
TBM Direction
4th 5th 6th
Legend: TBM Direction

Intervention Location
Figure 44: Sketch of the Proposed Cutter-head Intervention Locations
Cutter Head Intervention under Compressed Air
Personnel
Personnel involved in compressed work shall have clear responsibilities and proper training. Only
medically fit compressed air work personnel are allowed to work under compressed air.
Compressed air work procedure
The procedures and protocols for compressed air work shall be based on local requirements and
regulations. Main procedures and protocol to be established are as follows:

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Manlock, compressed air system, medical lock design specification.
Procedures for compression and decompression – guideline for work duration in

compressed air, compression and decompression table and etc.
Procedures to enter excavation chamber – inspection of air quality, inspection of stability of

excavation face, communication procedures, interlocking of cutterhead head and other
TBM function to ensure compressed air worker safety and etc.
Medical requirement – medical examination of working, proper record time in compressed

air work, requirement for medical lock attendant and etc.
Safety requirement – proper working platform in excavation chamber, communication

between compressed air workers with other workers / lock attendant.
Emergency procedures – personnel injury, fire, power failure etc.
Cutter Tools Replacement Procedure
Face must be inspected by authorised personnel prior to commencement of any work in the
cutterhead.
Most disc cutter and cutting tool changes can be accessed through the material lock at 9
o’clock position. As an alternative, access through the manlock at 12 o’clock position can
be used to replace some face cutters and to access the centre cutters.
Walkway and working platform in excavation chamber can be set up by attached platform
plate to platform support that have been fabricated to the TBM bulkhead. These platforms
are removable once cutter tools replacement is completed.
Platform plates
(supporting ear and
hexagon screw) setup on
bulkhead) Platform plates
All personnel shall be equipped with proper personnel protective equipment such as; safety
helmet, safety harness, safety goggles, gloves, safety shoes and etc.
Transporting of Disc cutter to Excavation Chamber
Deliver disc cutter with segment feeder to the erector pick up area

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Deliver Disc cutter to shield platform by means of erection rotation
Material lock
Shield
Platform

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Lift disc cutter up and place it on the materials lock transportation rail using chain block attached
to lifting eye provide.
Transfer the disc cutter to the excavation chamber via transportation rail. Compressed and
decompressed the material lock ae required.
Material Lock Transportation rail

Lock

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Lift the disc cutter working position at 6/ 9/ 12 o’clock using chain block attached to lifting lug
provided.
Cutter
replacement
platform
Ladder
Procedures for Face Check
Permit to work
A permit to work (PTW) system shall be used before entering into the cutter head with or without
compressed air. The PTW system ensures that safe work procedures are implemented properly and
serves as a means of communication among the site management, supervisors and workers. The
permit needs to be approved by the authorized personnel prior to cutter head intervention.
Inspection and verification procedure
Once TBM advance is completed and prior to any intervention, a monitoring array should
be established on the surface above the TBM and baseline readings are taken.
Ensure Compressed Air system is in working order including medical lock and standby
facilities.
Ensure all personnel have been suitably trained and are medically fit to enter compressed
air.
Confirm communication system and backup system between man-lock, man-lock attendant,
compressor attendant and emergency are in working order.

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Start low pressure compressed air system and check for leaks in the feed lines on the
surface, within the tunnel and at the TBM.
Set compressed air pressure on mass controller to be equal to the recommended initial
compressed air pressure for the specific and open valves in the bulkhead.
Purge/circulate air into the cutter head and monitor the exhaust air quality in accordance
with the required environmental parameters.
Inspection personnel shall undergo compression.
Before entering the cutter head the main TBM key is removed and held by the man-lock
attendant. A notice placed in the TBM operation room – “Men Working in the Cutter head –
DO NOT OPERATE”. This sign should also be written in Korean, Thai and any other
applicable languages.
Once the pressure gauges in the main man-lock chamber are equal to those within the
cutter head, the inspection personnel will open the 1” equalizing valve between the two.
The inspection personnel then open the in-bye door to the cutter head working chamber.
Lighting will be connected to a socket in the main man-lock chamber to allow a visual
inspection of the exposed face. The in-bye door between the man lock and cutter head
chamber must be left open while doors between the main lock and rear lock are closed at
all times during inspection and works in the cutter head under compressed air.
Visual inspection of the face shall be done wherein the face must be confirmed to be stable
with no unacceptable groundwater inflows and air losses are acceptable.
The specific check level for each intervention may be modified by the QP (D) as required
per data available on the prevailing soil conditions as the tunnel progresses.
Surface settlement readings shall be taken in accordance with the specified monitoring
requirements.
If groundwater inflows and/or settlements start to occur, the air pressure shall be increased
and the procedures for working under compressed air follow.
Ground Treatment for Cutter Head Intervention
The Contractor proposes grouting for the treatment of ground at every location of the cutter head
intervention. Further detail for the grouting process is presented in Section 6 Ground Improvement.

CONTRACT T316
TBM Start-up Procedure
Once the Tunnel Manager or Senior Engineer has authorized the TBM start-up, the TBM operator
will remove the "Men in the Chamber" signage from the TBM control panel and place the key into the
control panel.
After cutter intervention and before the start-up of the excavation, the chamber needs to be
decompressed. Excavation will then start slowly and carefully, filling-in the chamber with the
excavated soil.
The pressure in the chamber is slowly regained as the soil enters the chamber. In order to maintain
the stability, the pressures in tunnel face and the chamber must be equal and thus preventing face
collapse.
Maintaining EPBM Tunneling Rate
Transportation System
To keep the consistency of the EPB TBM tunneling rate, the Contractor will choose the appropriate
transportation system that can transport the spoil being produced by tunneling and deliver materials
such as concrete lining segment needed as the bored tunneling progresses.
Below succeeding paragraphs explains the purpose of the system.
Muck Disposal
The procedure applied for disposal of the muck off site during excavation is that the excavated
materials will come out of the excavation chamber through screw conveyor.
Then muck would be transported to main belt conveyor via a bridge belt conveyor operated at
pre-defined speed and discharged into the muck skips at the last back up.
From here, the muck skips will be transported with the help of locomotive and rolling stocks to
the shaft bottom.
Then the muck skip is lifted up with the gantry crane and the load dumped to the muck pit with
the help of tipping console at the shaft top. Then the excavator is deployed to load the muck
into the lorries and dump the materials to designated staging ground. Further explanation can
be referred to Section 9 Muck Removal System.
Locomotive
The locomotive will push the segment car and will pull the muck car to send the segment linings
to the segment erector at the back of the TBM and transportation of excavated materials to the
bottom of the shaft.

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Warning lights, horns & other necessary devices will be installed on the locomotives to ensure
that everybody in the tunnel especially those are with close proximity of the track will be alerted
for the approaching rolling stock.
Muck car
Muck cars are the part of rolling stocks to transport excavated materials from the last back up
to the bottom of the shaft.
Segment car
Segment cars are the part of the rolling stock that serves as the moving platform for the segment
linings (lowered by the gantry crane) to be sent at the segment erector. Two units of segment
cars are to be used and are interconnected with each other.
Man-riding car
Man-riding car, as the name implies, will transport personnel working in the tunnel to their
designated working area along the tunnel alignment.

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Rail and Sleeper
Rail and Sleepers are the tracks where the rolling stock convoy will traverse to convey the
segments to the designated location along the TBM rear body.
This is composed of composite steel materials. The main rail will be a 30 kg/m beam. The beam
will be supported by steel blocks on both sides in which the inner block will be connected by
bolts and the outer block will be by fillet weld. The base of the rail is a pre-fabricated steel
member. As the TBM advances, these items will be installed progressively with the aid of the
electric chain hoist mounted on the rear of the TBM. Details of the rail and sleepers are shown
below.
Soil Conditioning
Another important factor to maintain the EPBM tunneling is soil conditioning method. It is the
Contractor’s intention at the outset to attempt to derive some simple, high-level guidelines that if
followed would provide the highest probability of an EPBM reaching the best possible performance
in a mixed ground tunnel. Soil conditioning, as the main factor affecting advance rate, is the first line
of influence for the contractor/additive supplier/equipment supplier to influence how material is
excavated.
The Soil Conditioning plan, which will implement in front of the cutter head, impacts the entire
operation as the material must flow through the machine, out the heading, over the surface and off
the site. It affects every part of the job from the number of tool changes required to the amount of
cleanup in the heading and on the surface due to spillage.

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When this global impact of ground conditioning is taken into account, it makes good sense that
advance rates are closely correlated.
Earth pressure balance (EPB) tunneling machines are commonly used for the construction of tunnels
in soft soils. These machines use the excavated soil in a pressurized head chamber to apply a
support pressure to the tunnel face during excavation.
How an unstable face is supported in an EPB machine depends on effectively transferring a constant
pressure from the support medium to the surface of the face. If the support pressure is not constant,
but instead changes, the varying pressure inevitably leads to collapse of the face or heave on the
surface ground. A machine may be designed to work in “Ideal ground” conditions.
However, natural soils rarely have these properties, and conditioning of the soil is usually necessary
to change its properties to suit the machine. Effective soil conditioning significantly improves the
machine performance and control of the soil flow through the screw conveyor.
Soil conditioner is used to improve the following:
reduction of wear and reduction of power requirements at the cutter head;

improvement of the flow characteristics of the excavated soil;
better pressure control in the chamber and screw conveyor of an EPB machine; and
lubrication of the advancing tunnel shield.
There is no single treatment to successfully condition different types of soil. Furthermore, many
factors influence the specification and performance of soil conditioning treatments. For instance,
within the geotechnical factors that influence the treatments required for effective conditioning of the
soil are the size particle distribution, strength, permeability and water content.
Materials such as water, foams, polymers and bentonite slurries are used as conditioning agents.
Each agent has different properties producing varying effects on the properties of the different soils.
Their effect on different soils depends on whether they are used separately or in combination, their
concentration, their injection ratio and, in the case of foam, its expansion ratio value.
In order to achieve optimum performance with EPB machines, the excavated soil must form a
suitable plastic mass of soft consistency and low friction that can readily be extruded from the head
chamber through the screw conveyor. The EPB TBM proposed is equipped with various type of soil
conditioning system to ensure it best prepared to manage ground condition such as Fluvial Sand and
Fluvial Clay.
Foam Injection system
The EPB TBM is equipped with independent foam pump and foam generator system. The
cutterhead is equipped with 5 independent pipe lines to allow same injection flow rates even
with different nozzle resistance pressures, which avoid mud cake on the cutterhead and

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excavation chamber. Foam injection is also possible at the TBM bulkhead and screw
conveyor. The TBM is equipped with a total of 8 sets of foam generators and foam pumps.
Bentonite Injection system
Premixed bentonite slurry is supplied to the TBM bentonite storage tank and then injected by
two pumps to injection nozzles in the cutter head, excavation chamber and screw conveyor as
required. Bentonite injection reduces wear and improves muck discharge performance by
increasing fine particles. Shield skin bentonite injection system is equipped. Bentonite is injected
through injection ports around the shield, which reduces frictional resistance and prevents the
shield from trapping.
Polymer Injection System
The TBM also has the ability to inject polymer to improve the ground condition when it is required.
Other supporting services
Probe Drill and advance grouting system
The TBM is designed to be capable of probe drilling and advance grouting from the TBM itself. Probe
drill can be used to probe the ground condition ahead of TBM and advance grouting from TBM allow
flexibility to grout from the TBM when grouting from surface is not possible.
Subject to grouting requirement and the grout mix design, component A pump can be used for
advance grouting.

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The probe drill will be installed at the erector and powered by the erector hydraulic system. Twelve
(12) advance grouting port around the middle shield skin and six (6) advance grouting ports through
the front shield bulkhead are designed for the purpose of probe drilling, grouting for ground
improvement and consolidation.
Active Tunnel Face Support
The EPB TBM is equipped with Active Tunnel Face support system. This system allows the face
pressure to be maintained by injecting bentonite into the excavation chamber to achieve the targeted
face pressure when sudden face pressure loss due to face collapse, encounter cavity and other
unforeseen condition.
This system is meant as a measure to maintain face pressure due to unforeseen event and
excavation is not permitted when this system is activated. Excavation shall only resume when earth
pressure balance has achieve targeted face pressure.
Segment Erection and Control of Tolerance
Erection of Pre-Cast Segments
While the TBM advances, the pre-cast segments will be unloaded by gantry crane from the segment
stock yard above the ground to the erector in the machine, which will be carried by segment
car/feeder.
Segments will be lowered by the gantry crane and put on to the segment cars which will then be
transported by a locomotive towards the TBM.
Then, the lifting pin type erector will pick up the segment on the feeder and set it in a position where

CONTRACT T316
it will be bolted to the last ring. Bolts will be used as per specified in the drawings and ensure stable
connection between the rings.
Segment Set-up & Water-proofing
Segments are to be transported into the tunnel after being equipped with gaskets. The process of
attaching the gaskets to the segment shall be done in the segment yard.
Before attaching the gasket to the segment, be sure to clean the grooves in segment using a brush
for perfect attachment.
The segment and tail part of shield machine to be cleaned before assembling them.
When assembling segments, care is taken to perfectly connect the pieces and rings with bolts being
properly fastened.
Segment Assembly
All the segments are equipped with taper rings, which consist of a left and right taper. The layout of
segment is alternately done left taper come after right taper and so on.
To provide a good alignment, the segment has to be assembled accordingly by each section, piece
by piece followed by the final section which is the segment key.
During the process the jack stroke will be retracted back to accommodate the segment and maintain
the clearance between tail skin and the segment.
Bolts for segment are hexagon bolt with nuts and plain washer.
Bolts are to be fastened to certain torque. They are to be refastened at the position that will not affect
jacking power of the shield machine.
Backfill Grouting
As the TBM advances, the annular gap between the outer face of the completed ring and the
excavated soil surface of the tunnel will be injected with backfill grout from the tail of shield,
simultaneously in order to provide a solid fill between tunnel and ground. This prevents settlement
or deformation of rings erected.
The gap behind the shield tail between the ground and the outside of the segments will be treated
with tail skin grouting of backfill grout in order to provide a solid bond between tunnel and ground.
This prevents from the settlement or deformation of rings erected.
The grouting will be completed as soon as the grout injection is done from shield tail.

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The volume of injection will be monitored at level gauges on the motor car in the back-up trailer. The
grouting pressures are electronically controlled and recorded. This will ensure the grout is always
under constant pressure.
In some cases, a 2nd grout injection is done behind the shield from the rings fixed as required by the
engineer or as per specification.
The injected volume shall depend on soil conditions. Optimal injection volume is required for areas
where ground water is present.
It will be on the basis that two separate hoses will be engaged wherein one hose is used for pumping
grout and the other is for pumping silica. Pressure gauge and valve are attached to grout trailer where
pressure of the grout and the amount of grout can be monitored by the TBM operator.
The contents are transported into two separate pipelines so that the mixture contents will not solidify
quickly. Solidified mixture will create blockage within the pipe and/or at injection area thus can cause
work delay. Tabulated below is the standard mixture design used for liquid A and liquid B. Liquids (A
& B) will be pumped into a wagon and are transported into the grouting trailer.
Mix design is subject to change after confirming the suitable mix design.
Material Mixture Rate (per m3) Grout Volume (m3/Ring)

Cement 250 kg
Bentonite 30 kg
A Liquid
Stabilizer 2.5 liter 4.58
Water 829 liter
B Liquid Silica 80 liter

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Laboratory trials will be carried out to confirm the above mixture is adequate for usage on bored
tunnel works. The mentioned laboratory test will be witnessed by the designated personnel.
Grouting pipes will be cleaned regularly or as necessarily required in order not to hinder any blockage
or any possible obstruction during the injection process. The cleaning process shall be done when
the TBM machine is not on operational stage. The cleaning element to be used is bentonite or
compressed air to clear any blockage within the pipeline.
Flood Protection Measures in Bored Tunnel
Flooding inside the Tunnel
Factors resulting into flooding inside the tunnel must be identified then mitigation measures must be
done and interpretations must be included in the GIBR. These factors include the groundwater
conditions, soil permeability, and atmospheric conditions. it has been interpreted in the GIBR.
Water may enter into the machine through four locations as follows: cutter head, tail skin sealing,
segment linings and shaft opening.
Preventing Floods
The following prevention measures must be considered to prevent floods inside the working area.
Tail Seal Grease Injection
The TBM shall have a provision for tail seal system that will prevent any ingress of water from
entering into the machine. The tail shield equipped with three rows of wire-brush of tail seal, with
mini-injection of tail seal grease between the segment and the tail skin to ensure water-tightness.
Gasket Installation
Prevention of water intrusion from segment lining can also be done from manufacturing the
gasket lined per segment. These gaskets must be inspected to its high quality before lining into
the segment.
Where water leakage rates into the tunnel are outside the specified limits the contractor may
propose to rectify this by treating the ground behind segment joints or by other means to stop
the leakage. If leakage is within acceptable limits but still evident on visual inspection, the
contractor shall install channeling in the caulking groove to prevent the water from flowing across
the inner face of the tunnel lining.
Backfill Grouting
Backfill grouting refers to sealing the gap from the outer diameter of the segment to the
excavation diameter. Mix Design must be strictly followed wherein suitable grout depending on
the ground condition surrounding the tunnel will be adopted. Also, the method used must be

CONTRACT T316
done accurately to avoid any exposed area of the tunnel to the ground.
Ground Dewatering
Where dewatering is used, it must be kept minimum. It is permitted once approved calculations
and in-situ tests showing that the effect of such dewatering will not cause settlement. Also, each
dewatering well shall be capable of individual adjustment and being shut down and isolated from
the rest of the system. Lowering of any groundwater levels by more than 10kN/m2 equivalent
pressure is prohibited. Standby equipment and spares shall be maintained on site at all times.
Tunnel Drainage during Construction
The removal of water in the tunnels during construction will be carried out using submersible pumps
located at intervals and at the lowest elevations along the tunnel.
Initially, the pump size will be as of 2” and will be replaced with larger pump depending on the quantity
of water. Larger pumps will be kept as back-up to avoid any in-case flooding.
Emergency Plan
If it appears that the flooding inside the tunnel is dangerous to others, evacuation will be activated
by the immediate supervisor/foreman. The following action must be taken by those on the affected
area.
Raise the alarm in the shaft bottom and communicate to shaft top signalman
Switch off all machinery and electrical equipment to prevent machine breakdown and
possible electrocution of workers
Start to evacuate from shaft bottom using access ladder or man cage
All persons must proceed to the Assembly Point for head count
Fire Prevention Measures in the Bored Tunnel
Fire inside the Tunnel
Fire prevention and fire protection measures for working in a confined space must be done. To be
able to do such, combustible materials used during construction will be identified.
Identified combustible materials are as follows.
Timber in headings and face
Accumulations of Timber and scrap timber, Paper cement bags, Straw, Oily rags and hemp,
Flammable liquids and gases
Cable and Wiring

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Electrical installations
Flame cutting and welding areas
Chemical storage areas
Hydraulic(Oil) systems
Upon the identification of the combustible materials, careful handling and proper storage is a must.
Signage also must be placed so that everybody will be aware of such combustible materials.
The amount of combustible materials, flammable liquids and compressed gases in confined space
must be kept to the minimum consistency with construction and safety requirements. Any such
materials not required must be removed to a storage area.
Fire Safety Plan
Fire Safety Plan is important to ensure that all necessary actions are taken to prevent fire and for the
protection of public, environment, personnel and assets in the event of an incident.
As such, the site will ensure that
Fire safety plans are documented, implemented and clearly communicated
Sufficient equipment, facilities and trained personnel to respond to emergencies
Simulations and drills are conducted on regular basis to train all site personnel,
subcontractors and workers on the procedures to be followed during an emergency
Fire safety plans are reviewed for the adequacy of the plan as the work progress
The firefighting equipment and testing of all alarm and detection devices installed on site
are carried out on weekly basis
Weekly inspections of escape routes, fire brigade access, fire fighting facilities are carried
out
All inspection records are documented
No petrol driven internal combustion engine are used underground
Emergency Plan
When there is a fire;
Raise the alarm in the shaft bottom and put off the fire if possible at the same time.
Report the fire at the site office stating
● Where the fire is?

CONTRACT T316
● What is on fire?
● What is being done to put off or contain it?
If it appears to be dangerous to others in any part of the site, activate evacuation through
the aid of the guidance of the supervisor/foreman.
Protective and Firefighting Equipment
Sufficient number of fire extinguishers at designated areas will be provided to put off fire. Vaporizing
liquid extinguishers are not to be used because the toxic nature of the products of combustion makes
them dangerous in a confined space.
Water or foam extinguishers are not to be used on live electrical equipment.
Personal Protective Equipment (PPE)
● Helmet mounted lights

● Flashlights, back light and spare batteries
● Oxygen masks and cylinder harness
● Safety glasses
● Emergency whistles and radio
● Firefighting Equipment
● Fire hose reel at shaft bottom
● Identified nearby fire hydrant
● Fire extinguishers
General Control Measures
The following measures must be informed to every workforce on site.
“Danger” or “No Smoking” warnings shall be permanently placed in the tanks and other
areas where fire can easily start. The signs must be written in English, Malay, Chinese,
Hindi and other applicable languages.
Constant site cleaning. Combustible material shall be removed from working area. No
burning of rubbish or debris shall be permitted.
Proper storage of flammable materials. All fuel storage tanks shall be properly grounded
and bonded. The capacity of the bond wall must accommodate 1.5 times of the tank volume.
It shall be provided with suitable types of fire extinguishers, placed on posts with a distance
of 3 to 5 meters from the tank.
Proper electrical installation and wirings of electrical equipment and facilities to prevent
short circuit problem. Conduct monthly electrical inspection by Licensed Electrical Worker
(LEW) for some faulty wiring and defects.

CONTRACT T316
Regularly check for any gas presence inside the tunnel or leakage from gas cylinders. The
ground area shall be protected to minimize the intrusion of liquids into the ground.
All oxygen and acetylene cylinders, full or empty shall have safety valves, shall be kept
separately in a shaded storage area, stored upright, tied off, capped, chained in place, and
periodically inspected.
Provide adequate numbers of fire extinguishers and placed strategically in the site premises
and tunnel shaft.
Welding operations, if any, shall only be permitted in designated controlled areas. Flash
back arrestors shall be used at all times. The welding works area shall be designated as a
“No Smoking” zone and a sign should be posted.
Gas detection inside the tunnel shall to be conducted on a daily basis prior to starting works.
Intercom system must be installed along the tunnel shaft to be used during emergency to
improve reaction time.
Fire Safety Measures for Electrical Supply
Electrical installations and equipment can cause fires either by overheating, arcing or sparking.
Overheating may cause direct fire risk but more often will cause progressive damage to insulation
followed by ultimate break down, with current leakage, arcing and sparking.
To avoid overheating, special precautions to ensure adequate cooling of electrical cables must be
taken. Smoke detection system must also be installed in certain locations during the construction of
bored tunnels especially on isolated places.
TBM Disassembly
Introduciton
EPB TBM shall be disassembled but not be retrieved at tunnel end drive which is at west end of
Amber Station. The Contractor will design the TBMs to be disassembled underground and retrieved
back within the completed tunnels for extraction from the launch shaft at the east end of TE23
Tanjong Rhu cut and cover tunnel. After the final breaking in at west end of TE25 Amber station, the
shield skins shall be left underground and fully grouted by the Contractor to stabilize the ground, fill
any gaps between the ground and shield skins, and seal off against any fines ingress and
groundwater leaks. Cast in-situ permanent lining shall be constructed by the Contractor from the last
segmental lining ring built within the shield skins to Amber Station headwall to form the permanent
tunnels.
The TBM shield shall be designed to support the full ground and groundwater loads without internal
bracings during the dismantling of internal components up to the completion of the cast in-situ

CONTRACT T316
permanent lining. The Contractor will provide the structural calculations, carry out monitoring on the
shield deformation during this period and submit the limits of deformation for the Engineer’s approval.
Before the TBM reaches the receiving shaft, close monitoring of the tunnel survey will be carried out
to ensure that the TBM reaches the design tunnel center as accurate as possible. The exact position
of TBM has to be located at least 100 m before approaching the termination point. Hence, precise
survey will be carried out to ensure the location of the TBM. If the TBM is not in the original alignment,
it will be brought to the original position within that 100 m length. Once the position is confirmed, the
TBM with its back-up facilities shall slowly bore its way through the receiving chamber until the whole
cutting head of the TBM penetrates through the receiving wall.
Simultaneously, when the installation of the last segment ring in the shaft has been completed, the
gaps between the segments and the shaft will be covered up. Images from the succeeding sections
show the sequence of disassembly and retrieval of TBM from end drive TE 25-Amber station and
Launching shaft TE23 - Tanjong Rhu cut & cover station accordingly.
TBM Disassembly
General
Before the TBM reaches the west end of TE25 - Amber Station of Contract T306, close monitoring
of the tunnel survey will be carried out to ensure that the TBM reaches the design tunnel center as
accurate as possible.
The exact position of TBM has to be located at least 100 m before approaching the termination point.
Hence, precise survey will be carried out to ensure the location of the TBM. If the TBM is not in the
original alignment, it will be brought to the original position within that 100 m length.
Once the position is confirmed, the TBM with its back-up facilities will slowly bore its way through the
receiving chamber until the whole cutting head of the TBM penetrates through the receiving wall.
Retrieval of the TBM may be at the receiving chamber or at the launching shaft depending on the
provision at the end of each tunnel drive.
If it will be by back retrieval method, shield skin will be left underground and to be fully grouted, thus
stabilizing the ground and making it free from water ingress and leakage.
Simultaneously, when the installation of the last segment ring in the shaft has been completed, the
gaps between the segments and the shaft will be covered up.

CONTRACT T316
Disassembly of TBM at west end if TE25-Amber Station of Contract T306
Step 1) Removal of Connection and Erector Platform Step 2) Removal of Articulation Cylinder and Erector Beam
Step 3) Removal of Man Lock and Thrust Cylinder Step 4) Removal of Intermediate Shield
Step 5) Move the Intermediate Shield on Trolley Step 6) Removal of Drive Unit
Step 7) Removal of Front Shield Step 8) Move the Front Shield on Trolley
The cutter head is naturally bigger than the ID of the lining thus it must be able to be dismantled into
smaller section. The basic design is for the cutter head to come in 2 or 3 parts (excluding the
connection ring to the main drive). As the forces on the cutter head are extreme the joint must be a
combination of bolting and welding. The welding will have to be gouged out and the bolts removed.

CONTRACT T316
TBM Retrieval at TE 23 - Tanjong Rhu Station of Contract T303
1) Pull out whole back-ups out of tunnel and move them back to surface.
2) Pull out screw conveyor out of tunnel.
TENDER DOCUMENT Page 162

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3) Pull out erector out of tunnel.
4) Disassemble and transfer components in shield man lock, support structure, thrust cylinders, articulation cylinder, etc. out of tunnel.

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5) Disassemble and transfer main drive, rotary joint, etc. out of tunnel.
6) Cut support plates in the shield, disassemble and transfer cutter head out of tunnel, leaving the skin plate of TBM
Figure 45: TBM Disassembly Sequence (Longitudinal View)

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Risk Mitigation
General
During the EPBM tunneling works, the neighboring surface buildings and structures may cause
serious problems. For this fact, there must have measures to protect them from cracking, sinking,
and tilting, such as grouting the subsoil of their foundations, or constructing partition-piles to separate
the ground between the tunnel and the structure.
This section will presents control measures to prevent an adverse impact to foundation structures
and buildings within the zone of influence during tunneling.
The following measures stated below to control or mitigate the impact of tunneling to any buildings
or structures will be further developed during actual execution of the work.
Control Measures
Prior to start of any tunneling works, the Contractor shall:
Conduct actual site survey
By conducting actual site survey along the tunnel alignment, Contractor can have the accurate
knowledge of the exact location and on how many existing structures and buildings which will be
affected during tunneling and can prepare a map and a list for the record purpose and be submitted
to Authority.
Geological Soil Condition Investigation and Ground Improvement
The Contractor will conduct geological soil test condition especially to those affected buildings and
structures in order to identify on what ground improvement will be appropriate to undertake.
Suggested locations for ground improvement are indicated in the ITT drawing and these will be
confirmed during actual site work.
Monitoring settlements & Ground movement
The Contractor shall establish a settlement monitoring plan for review prior to construction. The plan
shall identify the location of settlement monitoring points, reference benchmarks, survey frequency
and procedures, and reporting formats for the suspected affected buildings and structures.
Type of Monitoring instruments for monitoring building distortion and damage may include a
combination of the following:
Surface settlement/heaver gauges
Building settlement markers (conventional and GPS)
Tilt meters

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Crack monitoring gauges
Ground movement monitoring is necessary for the reason of studying its (ground) behavior (stand-
up time, vertical and horizontal ground relaxation rates and magnitude, dewatering affecting the
ground stability, etc.) to develop the means and methods of structures support/underpinning, ground
treatments.
Structure Assessment
Preconstruction and post-construction assessment reports shall be provided for critical structures,
namely those located within the zone of active excavation from the proposed tunnel centerline.
Communication to local community and concern authority
It is important to gather information prior to work to locals residing to the affected area and to the
local concern authority to know about the history of the affected area whether the surfaces were
preserved, gets flooded or some unnatural phenomena has been taking place which is unknown to
the Contractor so to report to Authority the earliest prior to work.
Protection Measures
Affected Buildings and Structures
EPB TBM will be used for tunneling, so ground settlement control starts with applying the
right pressure to the face. This has to go hand in hand with controlling the amount of muck
that is extracted from the face, to be in balance with the theoretical volume. Not doing this
has caused a lot of sinkholes in the past.
Careful and complete backfilling (grouting) of the segments, not to induce any further
subsidence. With these measures, surface settlements can be controlled.
Underpinning the building foundation by consolidation grouting before and after TBM pass
the building and installation of the monitoring system are necessary to reduce the ground
settlement.
If necessary for the important building structures to protect, compensation grouting will be
executed or otherforms of ground treatment under Engineers discretion.
The suggested protection measures above will further be developed actual site condition during
execution of the work.
Affected Utilities
General
All buried utilities, whether shallow or at depth, will be affected by settlements arising from tunnel
construction.

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Culverts and large pipes, such as sewerage, water or gas mains, may be distorted by the ground
movements and have additional loadings placed on their joints and barrels.
Particular problems can arise at the connections between linear pipelines and fixed structures
such as buildings, manholes etc.
Careful analysis is required in all cases to ensure that the pipes, taking account of their material
and physical condition in the ground, can sustain foreseeable imposed loadings and movements.
Fractured gas and water mains have the potential to cause major disruption and serious or
significant damage to third party interests.
Other utilities such as telecommunications networks can be similarly damaged from settlements
which can result in outage to important systems and cause major third party disruption and result
in significant commercial claims.
Safety Precaution
● Utility diversion
To prevent utilities from damaging during tunnel, it is a good practice to safely divert
sensitive utilities prior to tunnel construction with the consent of concern authority, as
unexpected movements can endanger them that might previously have been thought to be
at low risk.
● Utilities or cables that cannot be diverted

If underground cable or utilities cannot be diverted, the following steps will be taken to avoid
contact:
 Contact the appropriate service providers

 Look around for obvious signs of underground services, e.g. valves covers or
patching of the road surface
 Use locator’s to trace any services and mark the ground accordingly. Make sure
persons using these scanners are trained and understand their use
 Make sure that the person supervising excavation work has service plans and
knows how to use them
 Everyone carrying out the work should know about safe digging practices and
emergency procedures
 Survey the area for overhead obstructions such as electricity lines

CONTRACT T316
Existing DTSS between bored tunnel
The stacked Changi and Woodland bound bored tunnel will cross the existing DTSS prior to
driving through the softeye at west side of Katong Park Station. Existing DTSS is positioned
between two bored tunnels. The Contractor expects that there is a large impact when tunneling
has reached this point or location of the sewer.
Prior to tunneling the Contractor should liaise to the Engineer or Utility owner about the existing
sewer. Information such as reference layout drawings and other resource reference shall be
produce in regards with the existing sewer to produce a theoretical assessment.
The Contractor will survey the location point of the existing sewer base on the gathered
information.
Once located, geotechnical study is needed to determine the exact presence of granular
material where the affected sewer pipe is located. The study will include the plan for a procedure
on how it will be protected or strengthen during tunneling to prevent it from any damages. Core
samples are to be taken at the proposed location. Test result must be reviewed and approved
by the Engineer or owner prior to bore tunneling activities in the area.
Grouting will be considered to improve or strengthen the ground surrounding the affected DTSS.
Jet grouting method will be proposes for the improvement during this stage based on the
preliminary subsidence report. After award, further investigation will be conducted to learn more
what other types of ground improvement which is suited for every area that requires ground
improvement. The type of grouting method will depends on the result of the geological lab test
being conducted during the investigation.
When bored tunneling is at close range, bore tunneling in charge shall be informed so to be
more cautious during excavation and be more alert in operating the TBM when crossing the
existing DTSS. Other protective measures can be referred to Section 7.13 Protection to
Adjacent Buildings or Structures.

CONTRACT T316
Historical Subsurface objects in Tunneling
Introduction
Underground/ subsurface objects and debris are obstructions that conflict with the planned tunnel
alignment and are capable of preventing the forward progress of the tunneling machine.
Typically, such obstructions may consist of boulders, cobbles, trees, and construction debris such
as timber piles, sheet piles, abandoned utilities, concrete, timber, bricks, metal objects and historical
underground objects.
Identifying such obstructions is important because of the serious consequences of encountering one
with a tunneling machine.
It is potentially a fatal flaw if surface access is not available to recover the machine or remove the
obstruction.
In order to be able to adopt the proper approach it is critical to evaluate the possibility of encountering
obstructions, determine the nature and sizes of the obstructions.
Plan Program
If it requires, the Contractor’s engineering department will form a group to undertake obstacle
investigation program.
The goal of the obstacle research is to assess the type and extend of subsurface objects along the
alignment in general and more specifically in the bored tunnel sections to reduce the risks caused
by underground obstacles.
Examples of these risks range from the tunnel boring machine (TBM) encountering an unknown
obstacles jeopardizing the structural integrity of the tunnel as well as the delay in the work progress.
Research Group
The research will be carried out following a systematic approach under supervision of a multi-
disciplinary team including an archeologist, geophysical experts, as well as engineering geologist
and civil engineers.
Approach for identifying underground objects
The obstacle investigation will start with an intensive historical research. With the result of the desk
study, possible locations can be identified that may require further (field) investigation to obtain
answers concerning unresolved issues.
Desk Study Sources
● Topographic/ land/ Admiralty Maps

CONTRACT T316
● Air Photos (Old if available to present)

● Government Department, Boreholes, Piezometer, etc.
● Underground operators, utility Owners, Water, Sewage/Culverts/ stormwater,
Telecoms, Electrics, gas, Cable TVs, Rail, Highways, etc.
● Building/ Foundation Records, Owners, Building authority, etc.
● Authority’s Databases/ Archives/ Files Projects, Contractors
● Old books/ old photos during construction/ Personal accounts
● Libraries/ archeological Societies
Parallel study will be performed to identify and label obstacle investigation techniques that could be
used in a later stage to detect and investigate obstacles in situ.
Procedural solutions that can aid for obstacles investigation are the follows:
● Do detailed thorough study

● Gather all relevant information
● Checklists to ensure data searched properly
● Availability of Utility databases and Government data
● Instill an investigative / CSI type approach
● Ensure staff searching information know what they are looking for and what is
important
● Use common sense on what you see

CONTRACT T316
Obstruction or debris
Currently there is no definite information on what to be encountered during bored tunneling.

Obstruction can be sheet pile, bored pile, steel H pile etc.
Some examples of Removal method when obstruction or debris is encountered
Figure 46: Existing H-Pile Foundation Removal

CONTRACT T316
Figure 47: Sample Image of Existing Bored Pile Foundation Removal

CONTRACT T316
Muck Removal System
Introduction
This section will outline the details of Muck Removal System that the Contractor proposes to use in
the excavation of bored tunnels using the TBM to remove the muck from suspension. The method of
removing the mucked materials will be explained in this methodology briefly.
Procedure
Muck car or Rail Removal Method
The Contractor will employ an EPB TBM in the boring of twin tunnel. The excavated soil is removed
from the cutter head chamber by the screw conveyor (primary conveyor).
Screw conveyor is driven by oil hydraulic motors and is located at the lower part of the bulk head.
Screw conveyor is then connected to the secondary conveyor (conveyor belt) on which the muck will
be transported and loaded to the muck cars towed by locomotive
Gantry Cranes
Office, Warehouse & other Facilities
Shield EPBM
Screw Discharger
Muck Car & Locomotive Trolley
Figure 48: Muck Removal Arrangement
The locomotive will push the empty muck cars (often 3 or 4 per train) towards the machine and will
then stop the train when the first muck car is under the dumping end of the conveyor system.
The muck boxes are designed to accommodate the muck produced by one boring cycle of the TBM,
while also taking into account the 1.5 or 2.0 bulking factor (The bulking or swelling factor is the
expansion of the soil after being taken from its original setting).

CONTRACT T316
Figure 49: Muck Car Lifting Setup

As the muck cars fill up, the locomotive operator will need to gradually pull forward so that the train
of muck cars can be filled without stopping the TBM from excavating. Once all muck cars have been
filled, the locomotive will pull the full train to the entry shaft, where the gantry crane will remove and
dump each muck car into a dump truck for hauling the muck into the approved disposal area.
Switch track
The Contractor proposes the installation of a switch track that will help to increase production. A
switch track is a scissor-like rail that mechanically guides the train from one set of rails to another,
essentially forming a “Y.” The two sets of rails run parallel, stretching out long enough to hold the
length of train, which requires an individual “Y” switch track to be placed at both ends. For each
switch track installed, an additional train can be added. This will decrease the downtime for which
trains travel the tunnel, or increase the time that the TBM can be utilized.
Figure 50: Muck Car Switch Track

CONTRACT T316
Safety Features to prevent runaway
With a full train, it is clear that speed will be decreased due to the weight depending on the size of
the muck cars varying with the size of the muck box. It is also important that the rail be laid flat and
tied together tightly. Flaws in the rail can cause derails, which delay production.
Locomotive will always undergo proper maintenance prior to its use if possible, this action will prevent
issues with locomotives as the project continues, as well as prevent delays due to the decreased
downtime.
Breaks are to be installed to train and always be monitored and check from time to time especially
when travelling to a steep rail track either up or down direction.
Classification and Separation of Muck Materials
The disposed muck materials will be classified into good or bad materials in accordance to the
prescribed requirements in the technical specifications. The good materials will be collected and
stocked separately for site usage.
The muck materials will be classified in four categories as below
Suitable Material – Defined as only natural material which is deemed acceptable for use in
the works as fill material; this will be capable of being compacted to form a stable fill. This
soil can be categorized to coarse-grain soil and fine-grain soil.
Unsuitable Material – This soil cannot be further used for any other works. It is classified as
to being soft and does not contain waste or contaminated materials. It is grouped as marine
clay and Kallang formation cohesive soils.
Waste Material – This includes the soil that does not fall to the category of suitable and
unsuitable material. This may include hardcore, road base material, topsoil, vegetation,
general building waste and bentonite contaminated soil. Suitable and unsuitable material
which has excessive water content will also fall into this category.
Contaminated Material – This is soil that has an excessive amount of one or more of arsenic,
copper, cadmium, chromium, lead, mercury, zinc or nickel.

CONTRACT T316
Resources for Tunneling
EPB Type Tunnel Boring Machine
Table 8: Proposed EPB TBM
TBM Supplier Origin Type / Model
China Railway Engineering Equipment China EPB Model: CTE 6630E-0960

NFM
Group Co., Ltd. (CREG) France EPB Model: Earth Pressure Balance Ø 6.68m
Table 9: Major Personnel and Contractors
Item Remarks
Proposed Tunnel Manager Refer to Package 4.A
Proposed Tunnel Plant Manager Refer to Package 4.A
Proposed Tunnel Subcontractors KORI Holdings / Fukuyama Eng. & Const.
Proposed Tunnel Engineers Refer to Package 4.A and Manpower List
Segments Precaster KOMT / GEOSTR RV
Segment Mould Service Sung-Jin Mech. / Korean Mold Co.
Table 10: EPB TBM Highlights
EPB Tunnel Boring Machine Characteristics
Items Option 1 Option 2
TBM Type EPB Model: CTE 6630E-0960 EPB 6.68m

China Railway Engineering
TBM Manufacturer NFM
Equipment Group Co.,Ltd.
TBM Manufacturing Location China France
TBM Power (Hydraulic/ Electric) Electrical Drive Electrical
No. of Drive Motors 160 kW x 6 nos 160 kW x 6 nos
Screw Conveyor Length 13.6 m 12.5 m
No. of Screw Discharge Gates 2 nos. 2 nos.
TBM Cycle Time Duration 1 ~ 1.5 hrs., subject to logistic and 55 min. (assuming full
setup excavation in one go)
Cutter-head Rotation Speed 0 ~ 4 rpm 0 ~ 3.5 rpm
Cutter-head Opening Ratio 37 % for mixed ground cutterhead 48 %
Central Disc cutter: 6 nos

Single Disc Cutter: 29 nos.
Drag Bit: 40 nos
Gauge Scraper:8 nos
No. of Buckets and Scrappers 16 nos. (bucket drag bits)
Protection Bit: 8 nos
Welded ripper: 23 nos.
Outer ring wear protection: 16 nos
Over cutter: 2 nos

CONTRACT T316
EPB Tunnel Boring Machine Characteristics
Items Option 1 Option 2
Thrust Force 46510 kN max. 46500kN @350 bar

No. of backfill grout injection Injection Points:8 (4 standby) Injection Points:8 (4 standby)
points, nozzles and generators Component A&B pump: 4 Component A&B pump: 4
Grout Flushing Method Reverse Flushing Reverse Flushing
No. and Details of Man-Lock 1 set 1 set
Sacrificial Skin 1 (act as the TBM shield) 1 (act as the TBM shield)
No. of Tail skin Brush 4 rows 4 rows
Proposed Tunnel drive rate (initial Initial Drive: 2~4ring / month Initial Drive: 2~4ring / month
drive and main drive) Main Drive: 4~8ring / month Main Drive: 4~8ring / month
Foam injection Points: Foam injection Points:

● 5 on Cutterhead ● 6 on Cutterhead
● 5 on Bulkhead ● 4 on Bulkhead
● 6 on Screw Conveyor ● 2 on Screw Conveyor
Bentonite Injection: Bentonite Injection:

No. of stabilizing fluid
● 1 on Cutterhead ● 6 nos.
(foam/polymer/bentonite) injection
● 5 on Bulkhead
points. Nozzles and generators
● 6 on Screw Conveyor Polymer injection : shared
● through bulkhead, on both
Polymer injection : 2 on bulkhead sides of screw conveyor
Foam Generators: 8 nos. ● can be added through the
Bentonite generators: 1 no. foam nozzles on the
Polymer generators: 2 nos. cutterhead
Proposed ground conditioning
Foam Foam
agent for inherently unstable
ground (F1/Fill)
Ground Treatment Location Refer to proposed location for ground improvement
Project Reference of TBM Supplier
Table 11: China Railway Engineering Equipment Group Co.,Ltd (CREG)
Project Type of TBM Geological Condition
Tianjin Metro Line 3, Lot 10 EPB Silty clay
Soft ground with 80% ground

Thomson Line T227 EPB
improvement
Fuzhou Metro EPB Clay, Silty clay, Sand
Suzhou Metro Line 4 EPB Silty Clay, Powder sand
Table 12: Neyrpic Framatome Mécanique (NFM)
Project Type of TBM Geological Condition
Sao Paolo Metro Line 6, Brasil EPB Alluvium
Thomson Lot 222, Singapare EPB Clay
London Underground Northern Line Ext. EPB Clay/ Sand

CONTRACT T316
Plant and Equipment

Description Nos. Unit
EPB Type Shield TBM with Back-up Equipment 2 No
Locomotive 5 Nos
Muck Car 24 Nos
Material Car 4 Nos
Segment Car 8 Nos
Man Riding Car 2 No
Navigation System 2 Set
Fire Fighting System 2 Set
Gas Monitoring System 2 Set
Gantry Crane 2 No
Ventilation Equipment 2 Nos
Service Mobile Crane 1 No
Tunnel Segment Lining
General
This section briefly outlines the sources and the basic requirements of precast concrete plants to
assure the production of quality precast concrete products. Also an inspection and test plan for
precast tunnel lining segments from raw materials control, production control and finished products
storage is briefly explained.
The manufacturing involves the production of approximately 2,840 rings of precast reinforced
concrete tunnel lining segments. Each ring is formed by assembling 6 different type of segment,
namely S1, S2, S3, S4, S5 and S6 differentiate either by left hand taper or right hand taper.
Table 13: Types of Segment for Tunnel Lining
Type of Segment
Item Type of Ring
S1 S2 S3 S4 S5 S6
Left Hand
1 L1 L2 L3 L4 L5 L6
Taper
Right Hand
2 R1 R2 R3 R4 R5 R6
Taper
Production Plant
The Production plant required for the production of tunnel lining segment are the following:
a) Batching Pant e) Touch up area

b) Reinforcement fabrication area f) Coating area
c) Casting / demoulding area g) Storage area
d) Curing area h) Trial assembly area

CONTRACT T316
Manufacturers
Manufacturer No. 1
Company KOM Technologies (M) Sdn Bhd.

Country Malaysia
Year of Establishment 2009
Certificates
1. Certificates of Conformity (SS EN 206 1:2009)
2. ISO 9001:2008
3. OHSAS 18001 :2007
4. BCA Certificate of License
● License as a Specialist Builder (Precast concrete Work)
5. Membership for Federation of Malaysia Manufactures (FMM)
6. Membership of Tunneling & Underground Construction Society (Singapore) TUCCS
7. BCA Registered Contractor
● Workhead Application for CR10 Precast Concrete Works
Figure 51: Precast Layout Plan of KOM Technologies (M) Sdn Bhd

CONTRACT T316
Manufacturer No. 2
Company GEOSTR-RV PTE.LTD.

Country Singapore
Year of Establishment June 18th 2014 (Incorporation Date)
Certificates
1. ISO 9001:2008
2. BCA Certificate of License
● License as a Specialist Builder (Precast concrete Work)
3. 50 years experience precast tunnel segments in Japan
4. More than 40 per cent of market share
5. Produced more than 130,000 rings of segments
Figure 52: Precast Layout Plan GEOSTR RV (M)

CONTRACT T316
Quality and Laboratory
Purpose
Quality control plan for manufacturing of segment is prepared to fulfill requirements as below:
The quality objective to be obtained.
Specific allocation of responsibilities and authority for Prefabrication Yard.
Specific procedures and instructions to be applied.
List up Inspection and Testing Plan applied throughout the production operations.
During production of segments, the quality control plan may revise and updated as required;
subjecting to Authorities approval.
Laboratory
Quality control laboratory facilities and capabilities are as below:
Sieve analysis
Organic impurities
Moisture content test
Slump test
Making and curing of concrete cube
Testing cube compressive strength
Collecting, updating and analyzing records / trends
Calibration
Quality control department shall be responsible for ensuring laboratory equipment calibration records
are maintained and updated as per requirements and available for inspection at all time.
Quality Records
All quality records of testings, measurements and inspection shall be filed by Quality Assurance
engineer. All quality records during production phases shall always be accessible but shall never be
removed from files. A copy can be provided on request. The signed segment certificate shall be
handed over to Authority/Engineer on delivery.
Third Party Test
Third party test will be conducted by approved qualified external third party laboratory, on special

CONTRACT T316
test required by Authority, which is not able to be tested by internal laboratory.
Source of Materials
All incoming raw materials shall be inspected and/or tested, where applicable, according to the
approved inspection and test plan (ITP) before they are used. The incoming cement, reinforcement
bar and admixture shall be accompanied with the supplier’s testing report or certificate.
If any changes for source of raw material, change control process flow will be applied to seek an
approval from LTA and all material shall be sent to independent laboratory.
Table 14: Main Materials List
Supplier
Type of Material
Main Backup
Cement (Mascrete) Lafarge Holcim
Silica Fume Greco SF-90D Lafarge
Steel Bar Antara Steel Y K Hardware
Aggregate Swisslane Bentara Gemilang
Sand Sin Kian Fuat Kian Lien
Admixture RF611 Rheobuild 1100
Water Syarikat Air Johor (SAJ) Natural Source

CONTRACT T316
Production
Process Flow

CONTRACT T316
Work Sequence
1. Fabrication of Rebar 2. Mould Operation
3. Concrete Casting 4. Remove Mould & Trim Surface
5. Curing 6. Visual Inspection

CONTRACT T316
Fabrication
Mould Operation
The mould is assembled by closing the four side forms and fixed by bolting the side- forms
together.
The assembled moulds shall then be inspected for accuracy of placing the steel cages,
cast-in item, cleanliness and correct assembly of the moulds by the production supervisor
according to the pre-concreting checklist.
Plastic spacer or concrete spacer block shall be used and attached to the steel cage at
specific locations in order to control the concrete cover precisely.
After placing the steel cages and cast-in items, the moulds are closed.
All bolts and curve pins are tightened and screwed in properly.

CONTRACT T316
Figure 53: Moulds
Mould conditions shall be checked once every day by visual inspection for any deformity
just before placing reinforcement cage into the mould.
The steel mould shall be cleaned and water-base or oil-base mould oil shall be applied onto
the surface of the mould after every demoulding.
Dimensional checking for mould shall be done once a month and if necessary, the mould
shall be adjusted again by mould supplier.
A non-conformance report shall be issued by KOMT for a yellow or red-tagged mould with
the necessary corrective actions in order to avoid repetitive mistakes.
Any non-conformance shall be corrected before concreting co-inspection with LTA & main
contractor appointed inspector. Concreting will be continued 15 minutes after KOMT
inspection was carried out even without LTA or main contractor appointed inspector
inspection to avoid productivity is affected by delay of inspection.
Reinforcement Cages
Fabrication
● Jigs shall be used for fabrication of reinforcement cages.

● Steel reinforcements shall be bent and placed in jigs at the production facility to ensure
its accuracy and maintained in the position indicated in the drawing.
● Main bars should be MIG (CO2) welded at specific locations to make it firm and rigid
and tied together with the distribution bars using tying wire and the ends of the tying
wire shall be cut-off.
● To ensure the suitability of welding steel bar, demonstration will be carried out at
factory for Authority’s approval.
● Only accepted reinforcement cages are delivered to the casting yard for concreting.
● The reinforcement cage shall be inspected according to the reinforcement checklist. A
non-conformance report shall be issued reinforcement cages with the necessary
corrective actions in order to avoid repetitive mistakes.

CONTRACT T316
Figure 54: Reinforcement Cage
Placing to Mould
● Positioning of steel cage into the mould should be to drawing.

● Installation of the plastic spacer to the cage should be as per approved manufacturer’s
recommendations.
● Install cast in items (PVC sheath and grout socket).
● Store cast in items in a container nearby casting yard.
Concrete
Placing
● Only approved moulds are allowed for casting.

● The concrete shall be batched and transported from the batching plant to the casting
yard by using a two-staged transportation system using overhead hoppers.
● At the casting yard, concrete from the first overhead hopper is transferred into the
second concrete hopper, transported and discharged directly into the mould.
● During hot weather, additional precautions shall be taken to prevent premature setting
and loss of water during the placing and compaction of concrete in the formwork as
per the required standard specification.
● Batching plant technician will maintain records of every batch of concrete in the
computer print-out.
Compaction
● Vibration is performed for the first phase of compaction after filling the mould with 80%
of concrete.
● Cover the mould with mould cover and filled with concrete to 100% for the second
layer after the first phase of compaction.

CONTRACT T316
● Compact the concrete by means of vibrating table and direct internal poker vibrator.
● Do not apply internal poker vibrator by way of reinforcement nor shall vibrators be
allowed to touch formwork or other embedded items as far as practicable.
Finishing
● After compaction of concrete, the mould cover shall be opened. Top surface of
segment shall be worked by steel square pipe, which is longer than the width of
segments to get the accurate thickness of segment.
● Early trowelling – atleast within 30 minutes after working by square pipe, top surfaces
shall be trowelled by plastic troweller.
● c. Final trowelling – After 2-3 hours from the casting, top surface of segments shall be
finished by steel troweller.
● d. Surface finishing method shall achieve
Demoulding and Curing
Demoulding
● Measure with cube strength test the initial demoulding strength. Demould the segment
when the cube test achieves minimum strength of 10N/mm² or as per approved
requirement.
● Segments are lifted and put on timber by vacuum demoulding device with an overhead
crane after achieving the demoulding strength.
Curing
● Spray water mist on the segment inside the mould regularly and cover with plastic
sheet or tarpaulin to prevent the surface from being dried out after final surface
finishing.
● Remove the segments from the mould and dip into the water pool for 7days curing
after completion of demoulding strength test.
● Overhead crane is utilized in removing those segments from the pool.
● Curing measures shall commence immediately after compaction and surface finishing
with tarpaulin cover.
Coating
Coating should be solvent free or water based emulsion epoxy coating.
First coating
Coating is to be applied to segments immediately after water curing.
Coating may be applied by a brush in difficult areas such as bolt holes and recesses.

CONTRACT T316
For larger surface areas, it should be applied by roller, in which case it should always be
over-rolled.
Second Coating
The second coat is applied after 1st coat has dried sufficiently by touch dry of about 2 – 3
hours.
Prior to the second application, air holes on the extrados face shall be filled up with latex
(styrene butadiene) mixed with cement.
The consumption thickness of the second coat is as per the 1st coat.
The second coat shall be applied in a direction perpendicular to the 1st coat.
Handling, Storage and Delivery
Handling
After de-moulding, using vacuum device and a gantry crane, the segments shall be placed
in a prepared area for the necessary repairs.
After epoxy coating and repairing, the segments shall be turned 180º with intrados face
upwards by turning device, transported to a prepared storage area and stacked one ring
each by gantry crane with sling belt.
All lifting equipment shall be inspected certified to the relevant regulation annually.
Storage
The storage yard shall be leveled and compacted with hardcore.
The segments shall be supported by timber supports on firm and leveled ground.
Every precaution, which includes firm ground and over-stacking, shall be taken to prevent
subsidence from occurring.
The segments shall be stacked horizontally at the storage yard with intrados face upwards
by sling belt.
The segments shall be stacked 1 complete ring high and supported by timber, usually 90mm
x 90mm, at the storage area to prevent cracks from arising with the self-weight of the
segments.
Each parallel support shall have same distance.
The timbers used for stacking will be wrapped in plastic to prevent the coated surface of the
segment from leaving any marks.

CONTRACT T316
The facilities which shall be employed to handle the segments are overhead crane, flatbeds
and turning device.
Delivery
The delivery clerk shall issue the delivery order (D.O), attached together with steel cage
checklist and segment certificate QA/QC manager/engineer.
The lorry driver shall collect the loading slip and a copy of a delivery order (D.O) from the
delivery clerk and hand it over to the yard supervisor.
The segments shall be inspected by the yard supervisor and QA/QC engineer if they have
any non-conformance report (NCR) or reject.
The lorry driver shall sign the delivery order (D.O) after the segments have been loaded
onto the lorry.
The lorry driver shall hand over the copy of delivery order (D.O) to the QA/QC engineer or
yard supervisor.
The QA/QC engineer shall review and sign the delivery order (D.O) once the segments
conform to the requirements.
Upon unloading on site, segments shall be checked. If the segments are damaged during
the transport, Contractor shall be notified to do the necessary repairs on site.
Non-Conformance Report (NCR) may be issued by the Contractor for damaged segments
on the lorry before unloading.
All criteria shall be checked and approved at the factory yard before delivery by the related
parties, Authority’s representative, Contractor representative and the manufacturer.
Contingency Measure for Segment Production
The Contractor will settle all necessary requirements, such as the approval for the materials,
fabrication location, proper management plan, etc. to start in advance the production of segment
after contract award.
Below schedule shows how the Contractor will keep in parallel the production of precast segment to
bored tunneling works.
YEAR 1 YEAR 2
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
Working Days 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24
Production 60 120 180 180 180 180 180 180 180 180 180 180 180 180 180 180 140
Cumulative 60 180 360 540 720 900 1080 1260 1440 1620 1800 1980 2160 2340 2520 2700 2840 2840 2840
Consumption 48 120 192 288 288 288 288 288 288 288 288 176
Cumulative 48 168 360 648 936 1224 1512 1800 2088 2376 2664 2840
28 days 0 0 0 0 0 0 60 180 360 540 720 900 1032 1092 1080 972 864 756 648 540 432 324 176 0
Stock Balance 0 0 0 0 0 60 180 360 540 720 900 1080 1212 1272 1260 1152 1044 936 828 720 612 464 176 0
Delivery Planning case 2: Production Planning

TENDER DOCUMENT 1st month : 2 rings/day
Page 190 of :225
1st month 2.5 rings/day
2nd month : 5 rings/day 2nd month : 5 rings/day
3rd month : 8 rings/day 3rd~end month : 7.5 rings/day
4th~11month : 12 rings/day
CONTRACT T316

CONTRACT T316
Cross Passages and Shafts
Introduction
This part of the method statement aims to outline the procedures and sequences for the excavation
of cross passages and shafts utilizing the Sequential Excavation Method (SEM), including the
installation of all temporary works.
Under the scope of work of Contract T305, there are 2 cross passages that will be connected at
various locations along the tunnel alignment indicated on the drawings as required. Site location
layout is shown below. Figure 55: Location Layout for Cross Passages and Shafts
CROSS PASSAGE 2
WITH SUMP PIT AT
BOTTOM OF
ACCESS SHAFT
CROSS PASSAGE 1
Figure 55: Location Layout for Cross Passages and Shafts
Pre-Excavation Works Procedure
Installation/Dismantle of Temporary Bracing (Ring Beam)
The installation of bored tunnel temporary bracing girders will be installed before cross
passage/pump sump excavation works commence.
Each bracing has 5 rings which will be erected one by one and finally joined together to form the
temporary support of the bored tunnel while cross passage / pump sump excavation works.
Removal of Segment
The affected segments will be cut by stitch coring. The segments will be cut into smaller manageable
pieces, starting with the lower edge followed by the upper edge. The segment will be further cut
vertically for ease removing.

CONTRACT T316
In case of risk of premature segment piece dislodgement during drilling, tie-backs will be installed to
the tunnel bracings to hold the segment to prevent uncontrolled swinging of each piece of segment
during removal; a restraining chain will be fixed across the front before it is removed.
Construction Procedure
The excavation of cross passage and pump sump will be undertaken using drilling and splitting
method in the initial commencement of the excavation. This will be carried out for the initial 2.5 m
only.
Only half face excavation will be carried out in stages with 1.0m advancement per time. The crown
will be excavated first from the tunnel segment followed by invert.
Excavation will continue with the drill method, advancing half face at a time (Top heading and bench).
The Contractor will use manual excavation (using small excavator) to cross passages. When
encountering the excavation and cannot be removed by manual excavation, splitting method will be
used.
After splitting, the post inspection will be done by the shot-firer and geologist. The geologist and shot-
firer have to declare if the work is safe for the removal of the muck materials.
The removal, loading and hauling of excavated soil will be carried out by mini excavator and mini
dump trucks or locomotives depending on the diameter of cross passages. The muck removal
activities will be as follows:
Big chunk of materials may further be broken into smaller pieces by a hydraulic breaker
attached to the mini excavator

CONTRACT T316
The muck/soil will be collected and loaded into mini dump trucks or locomotives by mini
excavator
The mini dump trucks or locomotives will haul and unload the materials into the muck
collection area in the launching shaft
The muck materials at the bottom of launching shaft will then be lifted up to the ground and
directly loaded the muck into the dump trucks
The dump trucks will haul and dump the muck materials into the approved disposal areas
Installation of Temporary Support
Generally, the sequence of installation for initial supports is as follows.
Spraying of sealing shotcrete to the exposed faces
Installation of 1st layer wire mesh
Spraying of 1st layer shotcrete
Installation of lattice girder and rock bolt
Installation of 2nd layer wire mesh
Spraying of 2nd layer shotcrete
Wire mesh, Shotcrete and Lattice Girder
The wet mix will be delivered to site and transported to the concrete pump position at shaft. After
installation of wire mesh, the shotcrete will be applied using the wet shotcrete machine. Prior to start
of shotcreting, the nozzle will be directed away from the surface to be shotcreted until a uniform flow
is attained.
Spraying shall commence from the lowest point upward keeping the nozzle perpendicular and
approximately one (1) meter from the sprayed surface.

CONTRACT T316
The spraying angle around the arch will be changed to avoid shadow or void behind the arch. After
shotcreting, the rebounds will be cleaned and rock bolt will be installed. Loose materials at the invert
will be blown away
Erection of Lattice Girder
Each lattice girder will be tagged after the inspection. Particular care will be taken in the setting out
of the lattice girder to ensure the correct profile and alignment.
Prior to installation of lattice girder, the actual center point of the tunnel at the particular location will
be established.
Using plumb bob, the vertical alignment will be marked at the sealing shotcrete on the crown. Depth
pins will also be drilled and installed along the lattice girder location which will serve as temporary
holding points during erection.
Short timber plank will be installed at both side of the tunnel which will act as footing for stability
during installation.
Lattice girder will be erected manually/service truck by placing the bottom end on top of the short
timber plank on the side of the tunnel and lifting the other end towards the crown.
The other piece of the lattice girder will be installed in the same manner. The two ends will meet at
the crown and will be connected by bolt.
Spacer bar will be installed and the lattice girder will be adjusted to correct position by aligning the
crown joint to the vertical alignment pre-marked on the sealing shotcrete on the crown and measuring
the lattice girder with respect to the center of the tunnel.
When alignment is confirmed, the bolts in all butt plates will be tightened. The spacing between the
lattice girders will be 1.0 meter unless otherwise specified.

CONTRACT T316
Typical Construction Sequence for Cross Passage
The following sequence of construction for cross passage is for tender purpose and this will be
altered to adapt the site condition during actual construction with the approval of the Engineer.
Sequences of work are shown below.
STEP 1: PREPARATION FOR ADIT WORKS
Install ground improvement block
Excavate cross Passage Shaft and Install shaft Temporary support
Drive Mainline TBM Tunnels
Perform secondary backfill annulus grouting for at least five segment rings before and after
adit opening
Perform probe drilling/grouting as required
STEP 2: EXCAVATION OF CONNECTING ADIT STARTING FROM TUNNELS
Installation of temporary steel bracing
Cut and break through tunnel lining
Staged excavation and installation of Temporary support. Top heading collar enlargement
at tunnel 1 is not excavated

CONTRACT T316
i. Excavation of 1st three rounds of top heading with immediate installation of wire
mesh
ii. Shotcrete must reach a minimum strength of 15 MPa. before the nest round. No
lattice girder shall be installed at collar location before collar enlargement
iii. Domed face of tunnel excavation – with face sealing of 50 mm shotcrete
iv. Incase excavation stops for more than 24 hours, thickness of face sealing
shotcrete shall be increased accordingly.
STEP 3: COLLAR EXCAVATION AT TUNNEL
Excavation and installation of temporary support for top heading collar enlargement at
tunnel 1.
STEP 4: EXCAVATION OF CONNECTING ADIT INVERT RING (RING CLOSURE)
Cut and break through lower portion of tunnel lining.
Staged excavation and installation of temporary support
i. Excavation of 1st two rounds of invert with immediate installation of wire mesh,
lattice girder and application of shotcrete after each round (Ring Closure)
ii. Shotcrete must reach a minimum strength of 15 MPa before the next round
Ring closure distance ≤ 4 rounds lengths.

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STEP 5: CONTINUE STAGED EXCAVATION & TEMPORARY SUPPORT TO ESCAPE SHAFT
Staged excavation and installation of remaining temporary support in adit with immediate
installation of lattice girder and application of shotcrete after each round
Breakthrough temporary support in vertical access shaft
STEP 6: INSTALLATION OF STEEL FRAME
Install permanent steel frame in permanent adit opening.
Installation of water proofing membrane re-injectable grout tube and hydrophilic strips
around man-line tunnel opening and shaft opening.

CONTRACT T316
STEP 7: COMPLETION ADIT
Installation of reinforce and formworks
Installation of permanent works concrete
Removal of temporary bracing in tunnel after concrete collar has reached the minimum 28
day compressive strength of 40 MPa.
Typical Construction Sequence for Cross Passage Shaft
Introduction
Both cross passage shaft 1 and shaft 2 have the typical construction method. The only difference is
that sump shall be constructed to cross passage shaft 2. Shaft shall be constructed prior to cross
passage. The Contractor will prepare the design which satisfies the requirements provided by the
Authority/ Engineer. Prior to constructing the shafts, site setting out shall be executed; temporary
works such as SBP wall and ground improvement shall be installed.
The following sections and figures below briefly show the information of Cross Passages shafts and
sequence of construction.
Cross Passages Shafts Plan, Section and Construction Sequences
Figures below show the difference between Shaft 1 & 2 sections.
SECANT BORED PILE WALL

(TEMPORARY WORKS OF CROSS PASSAGE SHAFT)
PERMANENT WALL OF CROSS PASSAGE SHAFT
CROSS PASSAGE SHAFT 1 SECTION CROSS PASSAGE SHAFT 2 SECTION
CROSS PASSAGE SHAFT PLAN
Figure 56: Cross Passage Plan & Section

CONTRACT T316
Construction Sequence
This construction sequence can be altered depending on the site condition during actual execution
on site with the approval of the Authority/Engineer.
Setting out/install SBP wall and ground improvement
Excavate to 101.0MRL and cast capping beam
Excavate to 1m below ring beam RB1
Excavate to 1m below ring beam RB2
Excavate to 1m below ring beam RB3 (applicable for shaft 2 only)
Excavate to FEL and cast temporary base slab
Completion of Cross Passage excavation
Cast permanent structures and backfill the gap between temporary shaft and permanent
structure with appropriate material
Cast permanent roof slab
Backfilling with suitable material and compaction
Hack capping beam and top 2m of SBP wall
Backfilling with suitable material and compaction up to ground level
Temporary Support/ Retaining Wall at Cross Passage Shaft
Secant Bored Pile
Secant Bored Piles will be used as temporary wall for the construction of the shaft of the cross
passage. The Contractor will design the temporary works in accordance with the standard
requirements.
Secant piles are interlocking piles that form a continuous watertight retaining wall, the basic layout
of the secant pile wall is a series of secant piles whereby the primary piles are un-reinforced and the
secondary piles are reinforced.
In special cases also the primary piles are reinforced by a rectangular reinforcement cage or as
specified in the documents.
A continuous reinforced concrete guide wall is constructed to pinpoint the location of each
overlapping pile; the amount of interlocking will be generally between 50 mm and 200 mm or required
by the design.

CONTRACT T316
Guide wall Construction
Prior to starting the installation of the pile wall a RC guide wall has to be installed.
Steps of Guide Wall installation:
Excavate ditch.
Set out axis and comer points (by
surveyor).
Place blinding concrete on level ground
as support for form work.
Erect prefabricated form work with
stiffeners
Countercheck location of form work by
surveying
Place concrete
Remove of form work

CONTRACT T316
Secant Bored Pile Installation
Alternate piles (known as "female", "hard" or "primary" piles) are drilled inside the temporary steel
casing and constructed without reinforcement using a slow setting concrete.
]Temporary casing is extracted while the concrete has not fully set and heavy casing is then driven
into the intervening pile location cutting into the fresh concrete of the adjacent female piles.
The "male", "soft" or "secondary" piles are then promptly drilled.
The secondary pile steel cage reinforcement is inserted and structural concrete is poured adhering
to the primary pile concrete on either side to form a watertight continuous wall.
Primary Pile Construction
Installation of temporary casing and drilling of primary pile
The temporary casing string will be formed of sections of 2 to 5 meters which will be connected by
means of flush screwed joints. A pilot hole of between 1 and 3m will be bored for first casing
installation.
The first casing tube is equipped with a casing shoe (equipped with a ring of cutting teeth) for
penetration/cutting of firm soils, concrete and other obstacles. It will be connected to the rotary drive
adapter of the boring rig, i.e. Bauer BG.
The operator of the boring rig will bring the first double wall casing section casing into exact position
with the help of the guide wall.
Before rotating the double wall casing into the ground by the high torque of the rotary drive of the
boring rig, the casing shall be adjusted to the vertical position by means of a precise spirit level
attached to the casing.
After the casing has been rotated few meters into the ground, the verticality of the casing shall be
again controlled by using a spirit level against the double wall casing and/or by two plumb-bobs/
plummet placed orthogonally at least 5m to 10m away from the casing.
Each time two axis of the casing have to be measured. The allowable tolerance for the inclination of
the casing is as per specification.
Each time a casing section has been rotated into the ground, excavation with auger and bucket is
performed until the excavation inside the casing has reached the lower end of the casing. These
processes continue until toe of casing reaches the required depth.
When very hard soil or rock is encountered, boring below casing may have to be carried out to
facilitate the installation of casing into hard layer.

CONTRACT T316
● For drilling in soil layer - auger and bucket
● For drilling in rock layer - auger, bucket and core barrel
If driving of the casing by rotary drive alone is getting difficult at depth oscillator may be used. Figure
below shows the installation sequence of the casing string.
Primary Pile Concrete Pouring
For a fluid filled bore, concreting shall be carried out using tremie method. The tremie pipe diameter
shall be at least ID-200 mm assembled in 3 m to 5 m sections, shorter sections near the top. The
tremie pipe shall be watertight and shall extend to the 200 mm to 300 mm from the borehole base.
It is top off with a conical hopper to receive concrete. Before discharging any concrete, a quantity of
vermiculite pellets shall be placed into the pipe to form a 200 mm – 300 mm length plug above the
fluid within the pipe.
The concrete shall then be discharged into the pipe through the conical hopper. The plug shall
prevent the first charge of concrete from mixing with the fluid.
Concrete pouring by tremie method will continue until the concrete level is approximately 1.0 m - 2.0
m (higher overcast may be required to allow for concrete to slump down during casing extraction)
above the cut-off level.
The tremie pipe shall be dismantled and shortened progressively, but at all times, maintaining at
least 2.0 m embedded within the concrete. For casting by tremie method, the concrete shall have a
slump of 150 mm to 200 mm with a minimum retarding of 4 to 6 hours.
For a dry bore, concrete pouring will be carried out using a short (approx. 1 m) conductor pipe with
a conical hopper on top to guide the discharge of the concrete.
Concreting shall continue until the concrete level is approximately 0.6 to 1.0 m above cut-off level
(higher overcast may be required to allow for concrete to slump down during case extraction). For
casting in a dry borehole, the concrete shall have a slump of 100 mm – 150 mm with a minimum
retarding of 4 hours.
Extraction of temporary casing
The extraction of casing may be carried out during and after concreting by means of an oscillator or
boring rig rotary drive adapter in sections, keeping the concrete level at least 1m above casing shoe
at all times.
After all the temporary casings have been withdrawn, the empty base will be backfilled with selected
boring material.
Secondary Pile Construction

CONTRACT T316
Installation of temporary casing and drilling of secondary pile
The construction procedure for installation of casing and drilling of secondary pile is similar to the
primary pile, except that the double wall casing will cut into adjacent concrete of primary piles. A high
torque capacity hydraulic boring rig such as Bauer BGs is required to carry such over cutting of
primary piles. The casing shoe is equipped with a ring of tungsten carbide teeth to cut into the primary
pile concrete to form the interlock.
Further excavation in uncased hole
After the casing has been filled up with fluid further excavation will be executed. During the drilling
operation the fluid level inside the hole has to be kept about 1m from top of casing.
In case of sudden loss of bentonite, the bore shall be backfilled with soil or the hole shall be treated
with expanding agents, concrete or grout.

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Estimated
Quantity/
Nos. Equipment Description output per Remarks
Capacity
day
1 Earth Drill boring 1 unit
2 boring overcoming of hard

Bauer BGs 1 unit
surface
3 handling of steel cages and 1 unit

Crawler Cranes
lifting concrete works 80~150 Ton
4 excavation and removal of

Excavator 1 unit
spoil
5 1 unit
Vibro Hammer extracting casing
7~12 ton
6 Welding Machine steel fastening /connection 2 units 1

Casing Mixing bentonite 2 units No / Day
7
8 Boring Tools Boring 2 units
9 2 units
Generator Welding and office use
100 kW
10 6 units
Pump (6 inch) Pumping
11 Chisel Breaking hard surface 2 units
12 Tremie Pipes,
Casting 1 set
Hoppers,Stoppers
13 Casing Oscillator Casing installation 2 units
In-line sump pit at Bored tunnel
The Sump pit below Wood Land Bored tunnel shall be constructed in accordance with the standard
specification requirements and drawings. Basically, drilling, grouting, bracing, shotcrete, concreting
etc. will be executed during construction.
Sump Construction Sequence is as below:
Bored tunnelling works for Woodlands bound

Perform probe drilling to detect groundwater and grouting if required
Install temporary steel bracing in tunnel
Remove the segment at tunnel invert
Staged excavation and installation of shotcrete support
Stage excavation as shown.(Round length of 1.0 m)
Install 200 mm shotcrete support

CONTRACT T316
Shotcrete must obtain 7MPa before the next lift until formation level
Domed invert of sump excavation and shotcrete
Install of grouting hose and hydrophilic strips
Install reinforcement and formworks
Concrete sump
Remove temporary steel bracing in tunnel after sump has reached the minimum 28 days
compressive strength
Bored tunnelling work for Changi bound
Repeat 1~13 for Changi bound
Figure 57: In-Line Sump Section

CONTRACT T316
Details of the Proposed TBM to be deployed
Technical Presentation of the Proposed TBM by CREG

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Technical Presentation of the Proposed TBM by NFM

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Attachment
Attachment 6.N.1 Project Reference
Attachment 6.N.2 Deeds of Collateral Warranty for TBM Supplier - 1
Attachment 6.N.2 Deeds of Collateral Warranty for TBM Supplier - 2

Overall Detailed MS - T316 - R00

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CONTRACT T316

Outline Method Statement

Scope of Works ......................................................................................................................... 7

Mobilization Plan ..................................................................................................................... 13

Temporary Site Offices and Facilities ................................................................................... 15

Site Establishment .................................................................................................................. 19

Ground Improvement .............................................................................................................. 32

Underground Infrastructure Building .................................................................................... 48

Tender Documents Page 1 of 225

Bored Piles at the Proposed Station and Entrances....................................................... 57

EPB TBM Bored Tunnels ...................................................................................................... 114

Muck Removal System ......................................................................................................... 173

Resources for Tunneling ...................................................................................................... 176

Cross Passages and Shafts ................................................................................................. 192

Tender Documents Page 2 of 225

In-line sump pit at Bored tunnel .................................................................................... 206

Details of the Proposed TBM to be deployed ..................................................................... 208

Attachment ............................................................................................................................. 225

Tender Documents Page 3 of 225

Tender Documents Page 4 of 225

Option 3: To Construct Shaft at E5 Aircraft Stand

Tender Documents Page 5 of 225

Project Site Location

Figure 1: Site Location Map

Tender Documents Page 6 of 225

b). Construction of underground infrastructure including all civil, structural, architectural,

i) Advise and assist in the development and implementation of Aerodrome Safety

iii) Prevention of incursion to aircraft movement areas;

iv) Obstacle and wildlife management;

v) Development of training and written procedure in relation to aerodrome safety;

Tender Documents Page 7 of 225

from CAG, CASS and all its stakeholders;

l). Prior to the underpinning works, the Contractor shall also:

ii) Design and carry out relocation of existing plantroom/equipment/services within

Tender Documents Page 8 of 225

Tender Documents Page 9 of 225

cc). Reinstatement of drainage elements affected by the Works in accordance to the

Tender Documents Page 10 of 225

mm). Design, construction, implementation and maintenance of a feasible temporary traffic

nn). Design, construction, implementation and maintenance of the required associated

Tender Documents Page 11 of 225

aaa). Design, coordination, provision, construction and maintenance of associated temporary

Tender Documents Page 12 of 225

Tender Documents Page 13 of 225

yards, mechanical workshops, warehouses, site offices, etc.

To establish detailed procedures for administration, supervision, and support activities.

Mobilization of Personnel and Equipment

Tender Documents Page 14 of 225

Temporary Site Offices and Facilities

Figure 2: Work site and Access road Layout

Figure 1: Work Site and Access Road Layout

Tender Documents Page 15 of 225

Site Utilization Plan

Figure 3: Site Utilization Plan Tentative Arrangement

Tender Documents Page 16 of 225

Detailed Traffic Control Plan

Several keys to consider for Traffic Control Plan

1. Work Duration 2. Work Location

3. Road Speed 4. Traffic Condition

5. Road Type 6. Type of Work

7. Road Location 8. Type of Operation

Implementation of Traffic Control Plan

Verify approval of Traffic Control Plan