ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR CIVIL WORKS

DIVISION 2 SITEWORK

SECTION 02400 PIPELINE CONSTRUCTION BY NON DISRUPTIVE METHOD

ADSSC/GSCW

Division 02

Section 02400

Pipeline Construction By Non Disruptive Method

Rev: 02

Jan. 2011

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General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description/ Purpose of Issue

01

April 2008

First Issue.

02

Jan. 2011

ADSSC new logo

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Division 02

Section 02400

Pipeline Construction By Non Disruptive Method

Rev: 02

Jan. 2011

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TABLE OF CONTENTS
1 GENERAL ....................................................................................................... 4 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.4.3 1.5 1.6 1.7 1.8 1.9 2 2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 SCOPE ................................................................................................ 4 RELATED DOCUMENTS ..................................................................... 4 STANDARDS ....................................................................................... 4 SUBMITTALS ....................................................................................... 5 PRODUCTS AND MATERIALS APPROVAL. ....................................... 5 METHOD STATEMENTS. ................................................................... 5 DRAWINGS AND CALCULATIONS. .................................................... 6 QUALITY CONTROL............................................................................ 7 DELIVERY, STORAGE, AND HANDLING............................................ 8 SAFETY ............................................................................................... 9 INVESTIGATION REQUIREMENTS .................................................. 10 DESIGN REQUIREMENTS ................................................................ 11 EQUIPMENT ...................................................................................... 13 TUNNELLING MACHINE ................................................................... 13 THRUST SYSTEM ............................................................................. 14 TUNNELLING SHIELDS FOR PIPEJACKING .................................... 14 NDM PIPES ....................................................................................... 15 REINFORCED CONCRETE JACKING PIPE ..................................... 15 COMPOSITE GRP JACKING PIPES ................................................. 16 STEEL CASING PIPE ........................................................................ 16 PIPE TESTING................................................................................... 16 JOINT PACKING ................................................................................ 17 LUBRICATING FLUID ........................................................................ 17 JOINT SEAL ....................................................................................... 17 GROUT .............................................................................................. 17 GENERAL .......................................................................................... 18 EXAMINATION................................................................................... 18 CAVITY GROUTING .......................................................................... 18 PITS/SHAFTS .................................................................................... 19 TUNNELLING .................................................................................... 20 PACKING ........................................................................................... 21 LINE AND LEVEL CONTROL ............................................................ 21 TOLERANCES ................................................................................... 21 DRILLING FLUID TESTS ................................................................... 22 GROUTING ........................................................................................ 23 MONITORING GROUND SURFACE MOVEMENT ............................ 23 PIPE TESTING................................................................................... 24 PROJECT RECORD DOCUMENTS .................................................. 24

PRODUCTS ................................................................................................... 13

EXECUTION .................................................................................................. 18

EXHIBIT 1 ............................................................................................................... 26

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Section 02400

Pipeline Construction By Non Disruptive Method

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1
1.1

GENERAL
SCOPE This section of the specification gives the requirements for pipeline construction by non disruptive methods (NDM) and should be read in conjunction with the Pipe Jacking Association of the UK publications and the Abu Dhabi Municipality guidelines and requirements as referenced in Clause 1.03 below.

1.2

RELATED DOCUMENTS The following sections of the specification shall be read in conjunction with this section. Section 01000-07 Section 01000-08 Section 01000-09 Section 02200 Section 02205 Section 02210 Section 02220 Section 03100 Section 03200 Section 03300 Section 03600 Submittals. Quality control. Materials and equipment. GRP and Pipelines. Materials, installation and testing. PVC-u Pipelines. Materials, installation and testing. HDPE Pipelines. Materials, installation and testing. RC Pipelines. Materials installation and testing. Concrete formwork. Concrete reinforcement. Cast in place concrete. Concrete protection and waterproofing.

1.3

STANDARDS All activities relating to this section of the specification shall comply with the following or approved equal standards. AASHTO HS20 BS 1377 BS 5228-1 BS 5228-2 44+100% - Surcharge loading. Methods of test for soils for civil engineering purposes. Code of practice for basic information and procedures for noise control. Guide for noise control legislation for construction and demolition, including road construction and maintenance. Concrete pipes and ancillary concrete products. Specification for unreinforced concrete pipes (including jacking pipes) with flexible joints Code of practice for site investigations. Code of practice for safety in tunnelling in the construction industry. Elastomeric seals. Material requirements for pipe joint seals used in water and drainage applications. Concrete pipes and fittings, unreinforced, steel fibre and reinforced Quality management systems.

BS 5911-1

BS 5930 BS 6164 BS EN 681-1 BS EN 1916 ISO 9000

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Pipe Jacking Association, UK Guide to best Practice for Installation of Pipe Jacks and Microtunnels. Pipe Jacking Association, UK An Introduction to Pipe Jacking and Microtunnelling design. Abu Dhabi Municipality Guidelines and Requirements for Planning and Design of Non Disruptive Road Crossings. 1.4 1.4.1 SUBMITTALS PRODUCTS AND MATERIALS APPROVAL. a) In order to verify compliance with the specification the Contractor shall submit information for all products and materials used in the Works to the Engineer for approval sufficiently in advance of their use in accordance with the Contract programme allowing for ordering and approval times. Reference shall also be made to Section 01000-09 of the specification on products and materials approval. Information to be submitted shall comprise but not necessarily be limited to: i. The manufacturers design calculations, complete and detailed specification and test results of the proposed pipes and fittings required for the Works including manufacturers certificates of compliance in accordance with Sections 02200, 02210 and 02220 of the specification. Information shall be given for every diameter in each class of pipe. ii. Should any details of the pipes and fittings be altered in any way during manufacture from those proposed and approved by the Engineer, submit for the Engineer's approval the revised details and test results. iii. Submit to the Engineer the results of all quality control tests carried out on the manufactured pipes and fittings as soon as practicable after testing and in any case not later than the time of delivery of the relevant pipes and fittings to the site. iv. Pipe manufacturers guarantee that the pipe and its materials are suitable for its intended use. v. Joint materials and gaskets. vi. Concrete protection systems. vii. Provide from the manufacturer a certificate of the bentonite powder showing the properties of each consignment delivered to the Site. Ensure that this certificate is available to the Engineer on request. The properties to be given by the manufacturer are the apparent viscosity range in pascal seconds and the gel strength range in pascals for solids in water.

1.4.2

METHOD STATEMENTS. a) The Contractor shall submit method statements to the Engineer for approval 4 weeks in advance of commencing the site activity in accordance with Section 01000-07 of the specification. These shall

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comprise but not necessarily be limited to: Geotechnical investigation report to include all information related to geotechnical and geophysical investigation undertaken and recommendations for tunnelling technique to be adopted, excavation support, and soil stabilisation if required including grouting of cavities if any. ii. List of all equipment and resources and programme of work showing allocation of equipment and resources. iii. Typical shift performance report. iv. Detailed step by step procedure describing how work will be carried out in particular how the different aspects of pipe jacking are monitored, such as angular deflection, jacking pressures, face pressures, packers etc. and then managed so that the interjacks are installed as required, deflection controlled and jacking pressures minimised. v. Submit independently authenticated test results to demonstrate that the joint packing complies with the specification. Include a graph of the stress/strain relationship over the range of conditions which will be encountered during the Works. vi. Method of excavation and removal. vii. Methodology for correcting line and level. viii. Support of existing services and adjacent structures. ix. Safety arrangements for compliance with safety requirements. x. Arrangement for dealing with ground water, taking due regard to controlling the loss of material and preventing settlement around pits/shafts, pipe/pit interfaces and tunnel face. xi. Dealing with different ground conditions. xii. Locking pipe in position during insertion of the next pipe. xiii. Sealing working shafts and reception pits during exiting and entering of pipe. xiv. Control of over break. xv. Grouting of cavities where applicable. xvi. Grout mix design and method of grouting. xvii. Details describing the measures to be taken to avoid the development and transfer of grout shrinkage or expansion stresses to the pipe and to avoid any adverse chemical reaction between the pipe and the concrete, grout or other materials comprising the pipeline. xviii. Handling and fixing of the inner line pipe in the case of tunnelling with oversize casing pipes. xix. Reuse/dumping of cuttings and slurry. xx. Layout of monitoring points for detection of surface movement. 1.4.3 DRAWINGS AND CALCULATIONS. a) The Contractor shall submit drawings to the Engineer for approval in advance of commencing the site activity in accordance with Section 01000-07 of the specification. These shall comprise but not necessarily be limited to: i.

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Working drawings showing on plan and section the method of supporting excavations. ii. The location of all pits/shafts including those indicated as permanent works in the design drawings, having due regard to existing services, minimising disruption to traffic and pedestrian movements and achieving the required system layouts, as shown on the tender drawings. iii. Foot print plans showing the working site areas at the thrust and reception pits/shafts, control room, pipe storage area, craneage area, slurry tank, generator etc. iv. Plan showing proposed traffic and pedestrian diversion proposals around all pits/shafts. v. Details of entry and exit pipe seals and seal rings in pits/shafts. vi. Longitudinal profiles from thrust to reception pits/shafts showing location of pipe joints, location of existing services and surface levels. vii. Calculations for thrust and reception pits/shafts which shall be designed to resist external soil and water pressure and stresses resulting from the jacking machine. viii. Calculations justifying allowable deflections at joints to limit damage to the joint from eccentric loading under drive and sealing limits and to ensure a completed pipeline with no visible leaks and within infiltration allowances. ix. Pipe calculations showing capability of pipe to resist jacking and friction forces in the axial direction and earth, AASHTO HS20 traffic, and surcharge loadings in the vertical direction. x. Calculations for friction loads, face loads, interjacks, jacking pressures etc. for the complete system, including thrust walls, which demonstrate how the pipes will be installed with no damage. xi. Calculations giving predicted settlements along and adjacent to route of pipeline. 1.5 QUALITY CONTROL a) Prior to dispatch of any product and/or material from source the Contractor shall notify the Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect and test the product and/or Material prior to delivery in accordance with Section 01000-08 of the specification. b) Products and materials shall be from a manufacturer/supplier who operates a quality system which is registered to ISO 9000 series or approved equal. c) To allow the Engineer to inspect the Works the contractor shall give the Engineer a minimum of 24 hours notice of carrying out the following activities on site. i. ii. iii.
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i.

Geotechnical investigation. Construction of thrust and reception pits/shafts. Undertaking each stage of NDM work.
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d) Ensure instrumentation is calibrated for each drive. Provide a valid calibration certificate. Ensure that the certificate is available to the Engineer upon request. e) The designer shall be an approved qualified Engineer experienced in the design of this work or similar. f) The installer shall be an approved company with specialised personnel in performing the work with minimum 5 years experience in the application of non disruptive method of pipeline construction of projects of similar size. i. All operators in the employment of the Contractor and his subcontractor shall be skilled and have a minimum 12 months experience in their respective trades and in particular in operating a machine similar to the machine used by the Contractor. Operators shall be subject to a probationary period of three months. Curriculum Vitae of key personnel and operators shall be submitted for approval by the Engineer and interviews may be taken at the discretion of the Engineer. The supervising operator who will perform the work for the Contract duration shall have a minimum of 5 years experience of similar works.

ii.

iii.

g) Approval for method statements shall be obtained from the Engineer and the concerned authorities including Abu Dhabi Municipality Road Section and Works Department as appropriate prior to excavation. h) Enclose with request for approval to carry out the Works from the concerned authorities, including the Works Department and the Abu Dhabi Municipality Roads Section, an undertaking in the form of Exhibit 1 enclosed at the end of this section formally executed, bearing the corporate seal and signed by the duly authorised signatory and endorsed by the executing authority. 1.6 DELIVERY, STORAGE, AND HANDLING a) Delivery, storage and handling of products and materials shall be in accordance with the manufacturer's recommendations, Section 0100009 of the specification and the following provisions. i. Delivery storage and handling shall at all times be performed in a manner to avoid product damage and be in accordance with the manufacturers recommendations. Pipes and fittings shall not come in contact with any sharp projections that may cause damage to the pipes and fittings during transportation loading and unloading. Ensure that pipes and fittings are well secured during transit and adequately supported along their length. Cover pipes and fittings of plastic materials during transportation. Do not allow pipe to overhang the end of a vehicle
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ii.

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General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

iii.

iv. v.

during transportation. Ensure that pipes and fittings are lifted using nylon or large diameter rope slings positioned at a quarter of the pipe length from each end. Do not allow the use of wire rope chains or unpadded forks or clamps on forklifts to lift pipes. Store pipes and fittings on a flat level area and follow manufacturers storing requirements . Stack non-crated pipes to the approval of the Engineer. Stack pipes of different sizes and thickness separately. Do not allow stacked pipes to exceed 2m in height or as recommended by the supplier whichever is the lesser.

Store GRP pipes and fittings under opaque cover and out of direct sunlight at all times. Maintain a free flow of air around the pipes at all times. vii. Coated and cured RC pipes shall be protected from UV exposure during storage ir required by coating manufacturer. viii. Store joint materials and gaskets in a well ventilated place free from exposure to sunlight and in their original packings until they are needed. ix. The Contractor shall visually inspect all products upon delivery to site and report any damage to the Engineer. Any products damaged during delivery, storage and handling shall be marked by the Contractor and set aside. Proposals for repair of any damaged products shall be submitted in writing to the Engineer for approval. Any damaged products deemed unsuitable for repair by the Engineer shall be removed from site and replaced. b) Store the lubrication material in a manner recommended by the supplier/manufacturer. 1.7 SAFETY a) Adopt safe working practices for tunnelling in accordance with provisions of BS 6164 and BS 5228: Parts 1 & 2. b) Allow only authorised personnel access to the site. c) Provide a Safety Officer, suitably experienced in tunnelling operations and with adequate authority to control and implement safe working practices. d) Provide and maintain suitable arrangements at site for personnel including: i. ii. iii. Telephone service. Telecommunication equipment between the control room and the working crew. Approved gas detectors.
Pipeline Construction By Non Disruptive Method

vi.

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iv. v. vi.

First aid kit. Emergency escape or breathing apparatus sets. Transport.

e) Provide a separate cage type ladder for each pit/shaft. f) Fence the shafts/pits on all sides with close steel panels of a minimum 1.8m in height equipped with orange safety warning lights. Join the panels, maximum space between the panels is 100mm, by steel rods supported on concrete blocks.

g) Provide adequate lighting and ventilation to the shafts/pits. Except where otherwise necessary, electricity shall be 110 volts from a centre tapped to earth (CTE) supply and up to 220 volts with use of ELCB protection. h) Provide an air-conditioned control room at the thrust pit/shaft with sufficient space for a desk and chair for one inspector. 1.8 INVESTIGATION REQUIREMENTS a) Obtain existing utility information, and excavate trial pits to locate and confirm services at pit/shaft locations and along the proposed tunnelling route as necessary. Obtain approval of utility authorities and relevant Department prior to the commencement of work. b) Carry out all geotechnical site investigation including ground water level monitoring, as considered necessary and as minimum at the proposed pits/shafts locations and along the proposed tunnelling route as necessary. c) Carry out a geophysical survey on a 10 metres wide strip along the proposed tunnelling route covering a depth range between ground level and up to 5 metres below the invert of the proposed tunnel. The objective of this survey is to detect any cavities or broken or collapsed subsurface strata, so that any such cavities or strata can be treated to allow tunnel construction. The general requirements and specification for the geophysical survey are as follows: i. ii. The survey shall be applicable to depths greater than 8m from existing ground level to invert of pipe. The survey shall provide information on both lateral and vertical extent of subsurface conditions together with the identification and classification of the geophysical materials in the subsurface sequence within the targeted depth of investigation. The information provided is to include details on likely size, depth and character of the features interpreted. The geophysical survey and all associated works shall only be carried out by specialist companies approved by the ADSSC. Before commencement of the survey, the Contractor shall submit the anticipated calibration work required to fully assess and
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iii. iv.

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v.

interpret the geophysical survey, and confirm his acceptance that the objectives of the survey are achievable. The geophysical survey technique to be used is that of resistivity imaging, and shall be generally conducted as follows: Establish benchmarks and topographically survey and inspect routes for interference. Undertake data acquisition and assess the data quality. Provide the preliminary resistivity section and preliminary interpretation result and undertake drilling of boreholes required for the calibration of the resistivity results. Provide precise interpretation of resistivity anomalies, supplement interpretation with physical evidences, drilling of boreholes, borehole logs and core photographs. Provide a survey report with the final interpreted sections, colour scale of sections should be standardised. The location of anomalies/cavities shall be marked and flagged by the Contractor at the exact location indicated by co-ordinates Easting and Northing.

vi.

One borehole in accordance with BS 5930 and BS 1377 for each 50 survey stations is included in the scope of geophysical survey in order to be used by the Contractor for calibration/interpretation of the survey results. Each borehole shall incorporate SPT at 1m intervals, groundwater level, rotary drilled coring of solid strata and photographs of cores.

vii. All basic data recording, preliminary and final interpretation and borehole records shall be included in the NDM design report. d) Notwithstanding the general requirements of Clause 1.8 above, soil conditions and ground conditions shall constitute the Contractors risk and the Contractor shall undertake such investigation as necessary to establish the sub surface conditions at no extra cost to ADSSC. 1.9 DESIGN REQUIREMENTS a) The Contractor is responsible for the design of all pipes including all joints, the thrust and reception pits/shafts including supports and thrust wall, the size of the pits/shafts to suit his method of construction and for the design of the jacking system in general. b) Ensure that the design of the thrust wall and any other associated Temporary Works is such as to prevent damage to any part of the Permanent Works or any immediately adjacent service or structure. c) Design thrust and reception pits/shafts to allow the safe operation of the plant, equipment and handling of the materials and to withstand all loading imposed by ground pressure, superimposed loads from surface structures and maximum proposed thrust force.

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d) Design pipes to withstand the maximum axial thrust with a factor of safety of 4 based on the full effective area and the ultimate compressive strength of the pipe material. For reinforced concrete pipes, use the full effective area at the joint. e) Where GRP or similar material pipes with concrete surround are proposed, the concrete surround shall be designed to withstand the maximum jacking force. The design shall also ensure that the GRP or similar material pipe is not subjected to any forces during installation. f) Design pipe joints in conjunction with resilient packing that avoids projections which could obstruct the travel of the pipe. Ensure that the joints will be watertight under axial loading and at the permissible deflection of the pipes.

g) Design joints for concrete pipes such that with an angular deflection of 10 degree. i. The areas available for transmitting the maximum permitted thrust force will be sufficient to ensure that there will be no pressure at any point greater than the maximum permissible pressure. There will be no damage to the pipe or loss of structural strength. There will be no ingress or egress of water or lubricant under the maximum operational or test pressures. There will be no ingress of soil/groundwater onto the bearing surfaces.

ii. iii. iv.

h) Design shall take account of the behaviour of the pipe joint at the maximum permitted angular deflection of 1 with the maximum permissible bearing stress in conjunction with the stress/strain relationship obtained from the packing compression tests and maximum jacking loads. j) Where it is proposed to construct certain section within larger diameter pipes and grout the annular space: i. Ensure that the difference between the external face of the inner pipe and the internal face of the outer pipe is not less than 150mm and no more than 250mm unless otherwise approved by the Engineer. The external pipe/sleeve may be of steel with full circumferential weld or reinforced concrete pipe. In either case, the casing pipe and the grout shall be regarded as sacrificial and the inner pipe shall be designed as a stand alone pipe, capable of withstanding installation and grouting forces and soil, traffic and groundwater loads. Where pipe-brackets, spider clamps, are used, rubber packers shall be placed between the steel brackets and pipe.

ii.

k) Limit the dimensions of drive and reception pits/shafts to the minimum required to construct the permanent works or to construct the pits/shafts, whichever is larger.
Pipeline Construction By Non Disruptive Method

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l)

Determine the excavated dimensions of the drive and reception pits/shafts as required to suit the site conditions. Minimum pit/shaft dimensions shall be used at all locations where utilities, roads or trees exist adjacent to the required pit/shaft locations.

m) Where it is proposed to use a tail tunnel as the reaction surface the maximum permitted thrust force is not to exceed the lesser of the following. i. ii. iii. The maximum permissible thrust force. 50% of the sum of the maximum forces recorded at the rigs used to construct the tail tunnel if the overbreak has not been grouted up. If the overbreak to the tail tunnel has been grouted up, 100% of the sum of the maximum forces recorded at the rigs used to construct the tail tunnel.

n) Any tail tunnel which has been used as a reaction surface shall pass the specified water tightness test at a time not less than 14 days after the load has been removed. o) Lubricant fluid holes shall be threaded to enable plugs to be screwed into the socket and withstand the external pressure. Non-return valves shall be fitted where opening a hole would permit ground loss. p) Confirm the tunnelling route is clear from cavities or obstructions or recommend and design for grouting of cavities and/or dealing with obstructions.

2
2.1

PRODUCTS
EQUIPMENT a) The Contractor shall use only NDM equipment that is appropriate for the intended installation, site and ground conditions, length of drive, and other relevant factors and can meet the contents of these specifications to the satisfaction of the Engineer. It is envisaged that the NDM equipment will have the following capabilities but the final choice of equipment will be the responsibility of the Contractor to the approval of the Engineer.

2.1.1

TUNNELLING MACHINE a) Steerable and incorporating hydraulic rams to move the articulated head. b) Designed to ensure no rotation or rolling during installation. c) Remote controlled and can transmit information such as jacking force, face pressure, length, roll, pitch, steering attitude, temperature, valves open or closed, cutter torque, rate of progress, slurry pressure, slurry

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flow, earth face pressure to a microprocessor console on the surface from where the system is operated. d) Incorporates meters and gauges to measure the slurry flow and pressures. e) Capable of operating under groundwater conditions as necessary with a hydrostatic balance not less than 3m head of water. f) Fitted with a calibrated laser target, robustly constructed and rigidly secured.

g) Guidance system shall be laser or an approved equivalent for the control of tunnel alignment. The guidance system shall be mounted independently of the thrust wall or machine jacking rig or anything else that may move during operations. 2.1.2 THRUST SYSTEM a) The rig shall distribute the thrust to the pipes via a thrust ring and packing. The jacks shall apply the thrust to the thrust ring by means of a symmetrical distribution. Interjack stations shall be used where frictional resistance or other causes would otherwise result in unacceptable thrust forces. b) If used, spacer blocks shall be true and free from any distortions. c) All thrust rings shall be true and free from any distortions and sufficiently stiff so as to transfer the load from the jacks uniformly to the packing. d) Other than at the shield, each group of jacks shall be interconnected to ensure that an evenly distributed load is applied to the thrust ring. e) Fitted with automatic thrust recording equipment monitoring load cells incorporated in each jack together with a pressure metering device. 2.1.3 TUNNELLING SHIELDS FOR PIPEJACKING a) Where considered necessary, the Contractor shall provide and maintain a shield suitable for excavating in the ground conditions as envisaged by him and in accordance with his chosen method of excavation. b) In determining the type of shield and method of excavation to be used, the Contractor shall take account of the need to ensure that the face of the excavation is adequately secured at all times such that ground loss is kept to a minimum and is controlled to prevent excessive ground loss. The shield shall be removed on completion of the tunnelling operation. c) Rotating excavating heads fitted to shields shall be capable of rotating clockwise and counter-clockwise.

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d) The shield shall be equipped with steering jacks and such heads, ploughs and copy cutters as may be required for adjusting the alignment of the pipes. e) Multiple lubricant injection points shall be provided within the shield in order to provide immediate ground support when necessary. f) In case of manual excavation, the shield should be pushed into the soil. The excavation should be limited to the soil falling inside the sleeve. No excavation should protrude outside the shield face.

2.2

NDM PIPES a) Pipes for NDM works shall be one of the following, unless otherwise approved by the Engineer: i. ii. iii. iv. Special purpose, reinforced concrete jacking pipe. Composite GRP pipe with reinforced concrete encasement. Steel casing pipe. Reinforced concrete jacking pipe or composite GRP pipe may also be used as casing pipes.

b) Ensure that all pipes including cut lengths and all fittings before despatch from the pipe manufacturer's works are indelibly marked as follows. The manufacturer's name, initials, or identification mark. The nominal internal diameter in mm. The length in m. Mark the classification i.e. pressure rating, stiffness. The date of manufacture and batch number. A stamp to show that they meet the required inspection requirements and hydraulic tests at the point of manufacturer. vii. Stencil in legible letters the pipe identification number on the inside and outside at each end. Ensure that the same number appears on all record sheets and documents relating to the manufacture delivery and testing of that pipe. viii. The manufacturing standard. ix. The project or contract number. 2.2.1 REINFORCED CONCRETE JACKING PIPE a) Reinforced concrete jacking pipe shall be manufactured in accordance with the requirements of Section 02220, BS EN 1916 and the following additional requirements. i. ii. iii. All jacking pipes shall have a coated steel reinforcing ring on the socket end to prevent cracking and spalling of the concrete. Configuration of the joints shall be altered as necessary to accommodate design requirements. Reinforcing steel and concrete strength shall be increased as necessary to accommodate design requirements.
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i. ii. iii. iv. v. vi.

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iv.

Pipes shall be protected externally with an epoxy coating to the requirements of Section 03600 of the specification. v. Grouting holes to be fitted as necessary in accordance with the method statement. vi. Lifting hooks or clamps may be fitted as necessary. vii. Other alterations shall be approved by the Engineer. b) When utilised as a casing pipe, internal plastic liners and exterior coatings are not required. 2.2.2 COMPOSITE GRP JACKING PIPES a) Composite GRP jacking pipes shall be manufactured from GRP pipes in accordance with the requirements of Section 02200, and with reinforced concrete encasement together with the following additional requirements. i. ii. iii. iv. Nominal length shall be 3m, unless otherwise approved by the Engineer. Joints and couplers may be altered as necessary to accommodate design requirements. Minimum stiffness shall be 10,000 N/m. A vinlyester flow coat shall be placed on the entire exterior GRP surface.

b) Formwork, reinforcement, concrete and concrete placement, finishing and curing shall be as specified in Sections 03100, 03200 and 03300 of the specification, along with the additional requirements below: i. ii. iii. 2.2.3 Minimum concrete strength shall be grade C50, unless otherwise approved by the Engineer. Grouting holes fitted as necessary. Lifting hooks or clamps fitted as necessary.

STEEL CASING PIPE a) Steel casing pipe for pipe jacking shall comply with the following requirements, unless otherwise approved by the Engineer. i. ii. iii. iv. Minimum wall thickness shall be 12mm. All joints shall be fully welded. All holes or openings shall be closed. Grouting spigots shall be fitted as necessary.

2.2.4

PIPE TESTING a) Quality control tests at the factory should include subjecting the pipe joints, at maximum permissible deflection, to: i. ii. Internal hydrostatic pressure of 1.5 times the working pressure or 1 bar for non pressure pipe. External pressure, vacuum, of 0.9bar.
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Abu Dhabi Sewerage Services Company (ADSSC)

b) Unless independently authenticated test results acceptable to the Engineer are available, two consecutive axial tests incorporating a 1 angular deflection with the application of double the maximum permissible thrust force or, if greater, of the greatest thrust force that the proposed thrust equipment can apply shall have been successfully conducted without any visible crushing, cracking or spalling of the pipe being evident before any pipes will be accepted for use. The tests shall be extended to record the loading at which any visible signs of failure become evident and shall be carried out in an approved manner to simulate actual working conditions. Pipes which have been submitted to the proof load test will not be permitted for use in the permanent works. 2.3 JOINT PACKING a) Joint packing material when subjected to the maximum permitted bearing pressure shall have under dry conditions: i. ii. A restoration after 1 hour of at least 65% of the original thickness. A compression of at least 50% of the original thickness. Independently authenticated test results to demonstrate that the packing complies with the specification shall be submitted and shall include a graph of the stress/strain relationship over the range of conditions which will be encountered during the Works.

b) The material used for packing to withstand all imposed loading applied during the installation of all pipes for each completed length without showing signs of deterioration or distress. 2.4 LUBRICATING FLUID It is envisaged that lubricating fluid shall be one of the following but the final choice of fluid will be the responsibility of the Contractor to the approval of the Engineer. Lubricating fluid shall generally be a polymer or bentonite based slurry lubrication material. In suitable ground conditions water alone may be used. For clay soils, non-aqueous lubricants shall be used. 2.5 JOINT SEAL The joint seal shall comprise one or more elastomeric rings complying with BS EN 681-1. 2.6 GROUT a) As overbreak grouting Portland cement and water as determined by geotechnical data and directed by the Engineer. Its nominal strength shall be at least 20N/mm. Admixtures shall be used only if tests have shown to the satisfaction of the Engineer that their use improves the properties of the grout, e.g. by increasing workability or slightly expanding the grout.

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b) As annular space filling a low strength grout or foam concrete shall be used and placed at low pressures. The density of the mix shall be in the range of 900 to 1200kg/m and the free water/cement not greater than 0.6. c) As cavities grouting Portland cement, Portland cement/sand or Portland cement/bentonite mortars as determined by ground investigation data.

3
3.1

EXECUTION
GENERAL a) Confine surface operations to pits/shafts and the area immediately adjacent to such shafts. Keep the working area to the minimum practicable for the proper construction of the works. b) Take any measures necessary to prevent damage or deterioration of the soil reaction face during the construction of the temporary and permanent works from whatever possible cause, such as ingress of water, softening, corrosive soil or loss of fines from a granular soil.

3.2

EXAMINATION a) Obtain existing utility information, and execute trial pits to locate and confirm services at pit/shaft locations and elsewhere as required. b) Pre construction photographs and pre construction grid survey of surface levels along the length of the proposed tunnel shall be taken by the Contractor.

3.3

CAVITY GROUTING a) In case cavities have been confirmed to exist along the tunnelling route by geophysical survey, such cavities shall be grouted. b) Grouting of existing cavities where required shall be carried out by means of drilling and pressure grouting of cement, cement/sand or cement/bentonite mortar to fill in the cavities and open fissures. This work shall be designed, carried out and tested by a specialised Contractor to a method statement approved by the Engineer. c) Boreholes shall be drilled vertically to the required depth below existing ground levels. Grouting shall be completed from the base of the boreholes up to ground levels. Verification boreholes shall be drilled, water pressure tested and grouted to assess the effectiveness of the treatment. d) Drilling shall be executed using rotary drilling methods with a casing advancer system to prevent borehole collapse in unconsolidated materials. Borehole diameter shall be a minimum of 100mm.

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General Specification for Civil Works

Abu Dhabi Sewerage Services Company (ADSSC)

e) Grouting shall be carried out in stages in accordance with the approved method statement. Inflatable packs shall be used as necessary to isolate areas requiring grouting and to enable pressure grouting. Grout shall be pumped through flexible hoses or steel pipes to the grout hole location. Grouting pressure shall be regulated up to a maximum of 2 bar unless ground conditions dictate otherwise. Grout shall be introduced to the grout hole via a tremmie pipe placed at the base of the borehole. The tremmie pipe shall not be removed until 100% grout is observed and maintained at the grout hole surface. 3.4 PITS/SHAFTS a) It is envisaged that pits/shafts will be constructed as follows but the final design will be the responsibility of the Contractor to the approval of the Engineer. b) The Contractor shall select between using inter-locked sheet pile cofferdam or reinforced concrete caisson as the most appropriate for the site conditions and for the soil profile. c) All the joints between caisson rings shall be sealed with joint sealant and the caisson grouted from outside in order to make it watertight. d) Interlocked steel sheet piles shall be braced by suitable steel framing welded to the sheet piles. No struts shall be used for bracing. The first set of bracing shall be 0.5m from the ground surface. e) The pit bottom shall be sealed with a concrete plug, which shall be placed underwater and designed to resist water uplift as well as forces from the jacking equipment to be installed in the pit. f) A reinforced concrete wall shall be provided in the thrust pit to resist the jacking force. A properly braced concrete wall shall be provided in the thrust and reception pits in order to install the exit and entry rings.

g) If a portion of the pit is to be constructed in rock, then this portion may be unsupported provided the rock layer is strong enough to safely resist all the expected forces and stresses. Contractor shall prove this by testing and calculation. Special precautions shall be taken to seal the interface between the caisson or sheet piles and the rock so that it is water and soil tight. Rock faces should also be treated if necessary to make them watertight. h) Maintain the pits/shafts dry prior to commencing and throughout tunnelling works. Dealing with groundwater were required shall be carried out carefully and slowly. Provide standby facilities. i) Thrust wall shall be: i.
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Perpendicular to the proposed line of thrust.

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ii.

iii. iv.

Sufficient to accept repeatedly the maximum permitted thrust force without undue movement and without thrusting directly off any part of the permanent works comprising any shaft, chamber or pumping station unless this is specifically designed to withstand the thrust reaction. Not joined to the jacking rig base. Any void between the soil face used to provide a reaction to the thrust force and the thrust wall filled completely with grout or concrete.

j) 3.5

Provide entry and exit sealing rings to ensure a watertight joint around the pipe at all times.

TUNNELLING a) Before any particular tunnelling commences, provide sufficient pipes, and, if required, provide intermediate jacking station assemblies to ensure continuous operation. b) Carry out the tunnel construction using the recommended accepted method to the satisfaction of the Engineer and to meet the contents of these specifications. c) Limit the thrust force to the maximum permissible as determined and based on submitted and approved calculations. d) Excavation rate not to exceed the horizontal drive rate throughout the operation. e) Prevent both subsidence and heave during all stages of the setting up, tunnelling operation and dismantling. f) Remove slurry/excavated soil mixture properly from the excavation, settle in a stilling basin and remove from the site to a suitable location. Avoid stock piling on site.

g) Maintain tunnel face support for balancing full earth pressure and groundwater pressures. h) Tunnelling operation shall be run continuously between drive and reception pits/shafts. j) Cuttings spoil removal and cutter face operation not permitted when the pipe thrust is not being carried out.

k) Fill the annular overbore voids around the outside of the pipe to avoid collapse and upward migration of the void prior to permanent grouting. Avoid drilling fluid injection overpressure. l) Casing and carrier pipes: place and join carrier pipe sections individually within the sleeve or mount on guide rails or trolleys in such a manner as
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to transmit the pulling/pushing forces through the carriage and not through the pipe. 3.6 PACKING a) Cut to dimensions that ensure the full bearing width of the joint is protected. Ensure that the initial thickness of the packing is such that the final joint gaps achieved upon completion of the pipeline are a minimum 8mm in width or in accordance with the pipe manufacturers recommendations. The joint gap shall have a tolerance of between 6mm and 15mm depending on jacking forces. b) Packing shall not be fixed over the full face of the pipe but stopped approximately 10mm round edges. c) Where there is no external pipe/sleeve, pipe installation shall continue until at least one additional length of pipe beyond the limit of construction is exposed. Where the pipe has failed, a second pipe shall be jacked through and inspected. The condition of the exposed pipe and its exterior coating shall be inspected by the Engineer. Where in the opinion of the Engineer the pipe or coating has been damaged during installation, the Contractor shall submit a proposal, for review by the Engineer, for demonstrating the adequacy of the pipeline installed. d) Seal gaps in the joints between the pipes with an approved material. 3.7 LINE AND LEVEL CONTROL a) The setting of the laser and target and the alignment of the tunnel relative to the laser beam shall be accurate and checked constantly. b) Where pipeline diameter allows, manual checking of line and level shall be carried out by conventional theodolite and level techniques. c) If the deviation exceeds the specified tolerance, work shall cease immediately and the Engineer informed forthwith. The Contractor shall submit proposals to rectify the deviation and work shall only recommence on the written instruction of the Engineer. 3.8 TOLERANCES a) Lateral deviation of any part of the pipeline shall be not more than 50mm. b) Level deviation of any part of the pipeline shall be not more than 20mm for pipe diameter up to 1800mm and 50mm for pipe diameter above 1800mm. c) Maximum lipping between the edges of adjacent pipes shall be not more than 5mm.

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d) Ground movement shall be limited to the following: i. ii. 3.9 Ground or roadway surface above the pipe centreline 3mm (unless the Roads Authorities requirement is more stringent). Adjacent structures 3mm.

DRILLING FLUID TESTS Carry out control tests on the bentonite suspension, using suitable apparatus. The density of freshly mixed bentonite suspension shall be measured daily as a check on the quality of the suspension being formed. The measuring device shall be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear strength and pH value shall be applied to bentonite supplied to the pipe bore. For average soil conditions the results shall generally be within the ranges in Table 3.8.1 below. Table 3.8.1 Bentonite Suspension Properties

Property Density Viscosity

Test Method Mud density balance Marsh cone method Fann viscometer Shearometer Fann viscometer

Range of Results Less than 1.10g/ml 30 to 90s less than 0.020Pa-s 1.4 to 10Pa 4 to 40Pa

Shear strength 10 minute gel strength

pH

pH indicator paper strips or 9.5 to 12 electrical pH meter

Notes to Table 3.8.1

1) 2) Where the Fann viscometer is specified, the fluid sample should be screened by a 300 m sieve before testing. The Contractor shall propose the frequency of testing bentonite slurry and the method and procedure of sampling for approval before the commencement of work. The frequency may subsequently be varied as required, depending on the consistency of the results obtained, subject to approval. Carry out tests until a consistent working pattern has been established, account being taken of the mixing process, any blending of freshly mixed bentonite suspension and previously used bentonite suspension, and any process which may be used to remove impurities from previously used bentonite suspension. When the results show consistent behaviour, the tests for shear strength and pH value may be discontinued, and tests to determine density and viscosity shall be carried out as agreed with the Engineer. In the event of a change in the established working pattern, tests for shear strength and pH value shall be reintroduced for a period if required.

3)

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3.10

GROUTING a) Upon completion of a section the grout should be pumped through all lubrication holes. The pressure and quantity of grout injected shall be calculated by the Contractor and approved by the Engineer. b) Commence grouting at the lower holes systematically working from one end of the pipejack to the other. Where injection holes can be opened without loss of ground, pump grout through the lower injection holes until it emerges from the upper holes. c) Monitor grouting progress continuously to ensure no heave. d) Protect the carrier pipe and joints from the possible adverse physical or chemical effect of grout. Wrap compressible material around the carrier pipe if required. e) Install a free venting standpipe of not less than 100mm diameter on the grout injection feed to restrict grouting pressures to a maximum of 1 bar. f) Plug lubrication holes watertight on completion and make good pipe lining or coating. Maintain the pressure of the lubricant when it is to be replaced by grout.

3.11

MONITORING GROUND SURFACE MOVEMENT a) The Contractor shall continuously monitor the ground surface adjacent to structures and buried utilities and shall control activities such as excavation, tunnelling and dewatering to prevent movement and or damage to existing structures. b) Install movement points and monitor prior to any excavation associated with the pipeline. c) Determine the optimum location for points to monitor existing structures to the approval of the Engineer. d) Provide monitoring points within the existing structures and on the road surface to the approval of the Engineer. Generally, monitoring points along the road surface shall be located along the pipe centreline on each side. The distance for the location of the monitoring points along the same line shall be calculated to fall within the HS 20 wheel loads in each lane. Points on existing structures shall be located approximately 500mm above the ground surface. Location of settlement points in the vicinity of the pits/shafts will be agreed with of the Engineer. e) Monitor all points with reference to benchmarks located outside the area of influence of the Works. Monitoring shall demonstrate repeatability to 3mm. f) Obtain the elevations of monitoring points as described below.
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For monitoring points within 20m of the heading, after each advance of 5m. ii. For monitoring points greater than 20m but less than 100m away from the heading, daily. iii. The monitoring point elevations shall be reported to the Engineer within 24 hours during the course of construction of the pipeline and related pits/shafts. g) Should surface movement occur greater than the specified limits, at any location affected by the Works, the Engineer may require modification of the method or sequence of the work or a shutdown of the work to make appropriate changes in the construction operation. Changes required to keep surface movement within the specified acceptable limits shall be made solely at the Contractors expense. h) Upon completion of the pipeline, continue to monitor point elevations during the maintenance period as required by the relevant authority, record findings and report to the Engineer on a monthly basis. If the specified limits are exceeded, report immediately and submit a proposal to rectify the road surface and prevent further settlement. 3.12 PIPE TESTING a) Conduct infiltration test upon completion of the permanent construction of the tunnel to verify the joints are water tight. The infiltration test shall be carried out after dewatering is stopped and the groundwater has attained normal levels. In the case of lined concrete pipes the leakage tests shall be carried out after installation and before the liners of the successive pipes are joined and sealed. After joining and sealing of the liners, there shall be no evidence of a build-up of groundwater pressure at the joints of the concrete pipe. b) Man entry pipelines shall be visually inspected only. Any leaks to be repaired/stopped. c) Infiltration or pipe deflection is not permitted in sections of pipelines underneath roads, paved areas and services. d) In the event of the works failing the test, for whatever reason, the Contractor shall take such remedial action as is necessary to correct the deficiencies, subject to the Engineer's approval of any methods proposed. The works shall be re-tested until such time as the works pass the test. 3.13 PROJECT RECORD DOCUMENTS a) The Contractor shall maintain and submit to the Engineer after each working shift a log which records the following: i. Identification number of pipes installed during shift and name of operator.
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i.

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Abu Dhabi Sewerage Services Company (ADSSC)

Strata encountered. Position and orientation of the lead ten pipes. Forces used on both main and interjack rams during driving of each pipe. v. Line and level. vi. Roll of pipejacking shield. vii. Maximum rate of advance. viii. Distance moved. ix. Thrust from ground on face of machine. x. Volume of lubricant used, location of injection and pressure at point of injection. xi. Volumes of material removed. xii. Volumes of grout used, the points of injection and pressure at the points of injection. xiii. Cutter torque. xiv. Slurry flow and pressure. xv. Supply pressure. xvi. Pitch of tunnelling machine. xvii. Deflection angle. xviii. Gas readings at the excavating face, oxygen, methane and hydrogen sulphide. xix. Gas readings in thrust pit. xx. Level records of ground surface or road pavement. xxi. Accident and stoppage, if any, with full explanation.

ii. iii. iv.

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EXHIBIT 1

UNDERTAKING
We undertake to inform the ......................*................. in the event of collapse, heave or settlement of a .......................*....................... road when we are carrying out excavation in, under or near to it. We hereby undertake to carry out the required reinstatement works exactly in accordance with ...................*.......................... specifications and to pay all compensations/entitlements for any accidents that may occur due to this road collapse, heave or settlement and any associated costs to replace/repair affected services.

This is our undertaking in this respect.

Contractor

Corporate Name..............................................................................................................

Chief Executive Officer.................................................................................................... Corporate Seal Endorsed by the Executing Authority

Name of Authority..........................................................................................................

Authorised Signatory.......................................................................................................

Signatory's name..........................................................................................................

Insert name of concerned Authority

END OF SECTION

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