TRENCHLESS INSTALLATION PROGRAM

HORIZONTAL DIRECTIONAL DRILLING (HDD), MICROTUNNELING PIPE JACKING

COPENHAGEN CONTRACTORS Maghater Complex * Building 31,3rd Floor, Office 19 Farwaniya , Kuwait WWW.CPHCON.COM * INFO@CPHCON.COM

Contents
Company Overview..................................................................................................................... 2 Horizontal Directional Drilling (HDD) ........................................................................................ 2 Microtunneling ........................................................................... Error! Bookmark not defined. Pipe Jacking and Auger Boring .............................................................................................. 11 Completed Projects .................................................................................................................. 15 Key Personnel ........................................................................................................................... 16

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Company Overview
Background
Copenhagen Contractors is a customer focused construction and contracting company, which undertakes all contracted works to relevant Western European, US or other International Standards, according to the demands of the individual client. Copenhagen Contractors, WWW.CPHCON.COM, was established in 2004 with a mission to supply and support international organizations around the globe with turnkey construction solutions and to generate the most efficient and effective results. Today, Copenhagen Contractors is recognized as a leading supplier of contingency logistics, specialized construction solutions, infrastructure projects and O&M services to civilian contractors, international organizations and governmental bodies. Together with our trusted partners Vadnais Microtunneling L.L.C., WWW.VADNAISLLC.COM, our team has a strong, established presence and many years experience of providing a complete range of timely services in support of electrical, oil and gas companies, municipalities, governments and international organizations worldwide. This experience ensures that not only have our systems and procedures been developed and refined over time to optimize support to locations throughout the world. We have also in place the personnel with the right technical experience and ability of operating in demanding environments in many parts of the globe. Copenhagen Contractors brings staff with a wealth of experience in construction, infrastructure projects and trenchless utilities installations in the Balkan region, the Middle East and Asia. For further information on Trenchless installation of utilities (by means of Horizontal Directional Drilling (HDD), Micro tunneling and Pipe Jacking) please contact: Mr. Jay Hicks Regional Manager, Middle East COPENHAGEN CONTRACTORS Maghater Complex Bld 31 Office 19, Farwaniya, Kuwait Mobile Kuwait: (+965) 65133508 Mobile UAE: (+971) 508088323 Office: (+965) 24773770 Fax: (+965) 24773771 E-mail: JAHI@CPHCON.COM Mr. Mahmoud Khader General Manager, Kuwait COPENHAGEN CONTRACTORS Maghater Complex Bld 31 Office 19, Farwaniya, Kuwait Mobile Kuwait: (+965) 65135001 Office [ +965] 24773770 Fax: [+965] 24773771 E-mail: MAKH@CPHCON.COM

I am confident you will find Copenhagen Contractors to be a reliable and professional partner in any construction project as well as an innovative and flexible sparring partner for future business opportunities

Horizontal Directional Drilling (HDD)

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Pipe/Cable-laying by Horizontal Directional Drilling (HDD) is one of the most innovative construction methods today. With the ever growing need for infrastructure around the globe, Copenhagen Contractors A/S is pleased to provide turnkey trenchless routing projects for infrastructural networks, installation of conduits to carry electric and fiber optic cable, pipelines carrying water, sewage, fuel and other products. Due to the versatility of the system the installation can be carried out under roads, buildings, runways, pipeline corridors and waterways and through even the most difficult soil conditions, cobblestone and pure rock.

Technology Overview and Benefits

Directional borings are fast and have the least environmental impact of any alternate method. The technology also allows conduit placement under obstacles and provides maximum protection and minimizes maintenance costs. During installation normal business operations are not interrupted which is of utmost importance in any operational environment. Directional borings have a predictable and short construction schedule and the major benefits are: Continuation of normal operation Avoidance of identified infrastructure installations Maintain integrity of roadways, buildings, and natural features Little or no disturbance to wetlands or nature conservators. Minimum site restoration

Copenhagen Contractors HDD at Kandahar Airfield, Afghanistan

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Technology and Services

Copenhagen Contractors A/S owns, maintains and operates a fleet of state-of-the-art horizontal drilling rigs. The D16X20, D36X50 and D100x120 II Series rigs and Drilling Fluid Mixing Systems are manufactured by Vermeer in Pella, Iowa, USA. The range of capacity in these rigs combined with a series of specialized drill bits and the R.A.T.T. (Rock Adaptable Terrain Tool) provide the opportunity to match the equipment to any field conditions in the Middle East, including rock and cobblestone conditions.

Vermeer D16x24 Series II NAVIGATOR rig

Vermeer D16x20 Series II NAVIGATOR

Loaded with many intelligent features on a compact frame, the D16x20 Series II is powered by a 65 hp/48 kW Kubota diesel engine, giving you 2,000 ft-lb/2,700 Nm of rotational torque and 1,600 lbs/71 kN of thrust/pullback. The onboard pump provides high flow in large-diameter bores for more efficient backreaming. 4

Vermeer D36x50 Series II NAVIGATOR rig.

Vermeer D36x50 Series II NAVIGATOR

With the highest power-to-size ratio in its class the D36x50 Series II is powered by a 140 hp (104 kw) engine and delivers 4928 ft-lb (6681 Nm) of rotary torque and 33,000 lb (14,969 kg) of thrust with 36,000 lb (16,329 kg) of pullback. It's narrowly designed rack and pinion design helps to maintain a small footprint for access into congested areas. The D36x50 is built to perform a wide range of medium diameter, moderate-to-long distance utility installations (up to 450 / 137 meters).

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Vermeer D36x50 Series II NAVIGATOR rig.

Vermeer D100x120 Series II NAVIGATOR

Power through a wide range of bores, even in difficult ground conditions, with the D100x120 Series II. Equipped with a 225 hp/150 kW John Deere 6068 Tier 3 diesel engine, the D100x120 Series II offers 12,000 ft-lb./16,270 Nm of rotational torque and 100,000 lbs/445 kN of thrust/pullback force.

Due to its compact design the HDD drilling rigs are able to operate in congested and hard-to-reach places.

Precision multiple pipe installation in three separate crossings.

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Copenhagen Contractors HDD Assets

MX240 Drilling Fluid Mixing System The MX240 Modular Drilling Fluid System is designed to provide fast mixing of high volumes of drilling fluid for large-diameter and long-distance HDD applications. The system features a 25 hp (18.6 kw) Kohler gas or 22 hp (16.4 kw) Hatz diesel engine supporting a 1000 gallon (3785 L) mixing tank.

Rock Adaptable Terrain Tool (R.A.T.T) Especially for very demanding soil conditions Copenhagen Contractors provides the Rock Adaptable Terrain Tool (R.A.T.T.). The R.A.T.T. offers operators the ability to drill and steer through varying soil conditions including soft soil, gravel, cobblestone and solid rock. 6

Drilling Bits, Reamers and Spare Parts Copenhagen Contractors uses Genuine Vermeer parts exclusively. All drill bits, reamers, shark teeth, cutters etc. are precision-crafted to match our Vermeer equipment exactly. This ensures that our HDD system runs as smoothly as possible, with the least amount of service and maintenance.

Bore Planning Copenhagen Contractors uses the Vermeer Atlas Bore Planning system to efficiently plan our bores. The bore planning software heightens professionalism by aiding the operator in preplanning the bore and comparing the planned bore path with the actual bore path.

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Locating System: The locating system is a system that verifies the proposed drill route establishing surface navigational systems (tolerance and accuracy) and testing of the survey systems to be used as down hole. The position of the underground drilling head is determined by the locator. To bore straight, steer and rotate the angle of direction and forward thrust will be applied.

Drilling Fluid (Bentonite) Bentonite based drilling fluids are used in both vertical and horizontal drilling. It is a colloidal clay mineral, compsed primarily of montmorillonite, especially chosen for its capacity to absorb enormous quantities of water. The absorption increases the distance between individual clay platelets and this mechanism in turn increases the viscosity of the fluid

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HDD fleet specifications

D16x20 Series II D36x50 Series II 15' D100x120 Series II

Weight

10,500 lbs (4,762.72 kg)

21,850 lbs (9,910.99 kg)

21,850 lbs (9,910.99 kg)

Engine make and model

Kubota 3,600

John Deere PowerTech 4,045HF275

John Deere 6,068

Gross Horsepower

65 hp (48.47 kw)

140 hp (104.4 kw)

225 hp (167.78 kw)

Thrust

16,000 lbs (7,257 kg)

33,000 lbs (14,968 kg)

100,000 lbs (45,359 kg)

Pullback

16,000 lbs (7,257 kg)

33,000 lbs (14,968 kg)

100,000 lbs (45,359 kg)

Minimum Bore Diameter Auxiliary Pump Flow at Maximum Engine RPM Auxiliary Pump Relief Pressure Thrust/Pullback Pump Flow at Max Engine RPM Thrust/Pullback Pump Relief Pressure

3.5" (8.89 cm)

3.5" (8.89 cm)

5" (12.7 cm) 8

26 gpm

47 gpm

20 gpm

3,300 psi (227.53 bar)

3,000 psi (206.84 bar)

3,000 psi (206.84 bar)

36 gpm (136.27 L/min)

33.06 gpm (125.3 L/min)

45 gpm (170.34 L/min)

3,335 psi (229.94 bar)

2,650 psi (182.71 bar)

2,650 psi (182.71 bar)

Beside the HDD rigs Copenhagen Contractors owns and operates a fleet of support vehicles, including but not limited to: Water Tankers, Tractors Trucks

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HDD Method Statement

Our HDD works can be divided into 3 independent stages, namely: 1. Pilot Bore The pilot bore is the first phase in any HDD project. The pilot bore is executed by directionally guiding the drill head along a determined path from entry point (rig side) to the exit point (pipe side). Machinery utilized for drilling the pilot bore in hard rock conditions are available and includes the R.A.T.T (Rock Adaptable Terrain Tools) to penetrate into hard rock conditions. During the pilot bore a sonde (transmitter) and a tracking (receiver) device are utilized to be able to precisely locate and steer the drill string underneath the surface. Pre-Reaming Pre-Reaming is done with the same machine as the machine that was used for drilling the pilot bore. Once the pilot bore is completed the drill head and tracking system is disconnected from the drill string and back reamers are installed. Back reaming is usually performed in stages until the final desired diameter of hole is reached, hence the pipe is ready to be pulled. The stages vary from site to site and from job to job depending on the specific circumstances of each. Copenhagen Contractors owns back reamers of various types and models and are selected as per the ground conditions they are to be operated in. In hard rock conditions Rock Back reamers will be utilized due to the higher performance and efficiency required Pipe Pulling Pipe pulling is the last phase before the job is done. The pipe is connected to the drill string and it is then pulled from the exit pit side towards the entry pit side (rig side). Copenhagen Contractors offers a wide variety of Pipes/Pipe Sleeves/Cables to be pulled depending on the project specifications.

2.

3.

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HDD Design Rules of thumb:

Every site is unique and every installation method will be selected to draw on the experience of Copenhagen Contractors A/S HDD engineer to meet the exact needs of the client and address the characteristics of the site. With this as a caveat, the following guidance has been described by directional boring designers and constructors: Mobilization and set up of the drilling equipment usually takes one day and includes site preparation and excavation. Under good conditions Copenhagen Contractors A/S can install 50-80 meters of pipe per day. A crew of one operator, one locator and two to three helpers shall be working on each rig. The locator shall take readings in short intervals and lead the operator drilling path A setback is needed for entrance and exit points and must be included in the length of the borehole. Setbacks range from 1 to 2 meters for each meter below grade of the installation. For example, for a placement 2 meters below grade, include 5 to 8 meters of boring on each side of the installation for the setbacks. To cool the drill head and flush the debris out of the hole drilling fluid mix (bentonite and other additives) are pumped into the drill string throughout all phases of the drilling. Cobblestones are the nemesis of directional drills and can deflect drill strings. Difficult-topenetrate conditions may increase the time needed to complete a project. Safety on site is ensured at all times, and safety gloves, shoes, reflective jackets are worn by the entire crew. De-mobilization usually takes one day and includes backfilling and compaction of the soil. The provision of Personal Protective Equipment (PPE) and implementation of Health & Safety (H&S) and Quality Assurance (QA) procedures are vital to a successful project. 10

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Pipe Jacking and Auger Boring

Copenhagen Contractors is proud to provide pipe jacking as part of our range of services. Pipe Jacking and Auger boring are specialist tunneling methods for installing underground pipelines with a minimum of surface disruption. The techniques are primarily used for sewer replacement and relining, gas and water mains, oil pipelines, electricity and telecommunication installations, culverts and subways. Where pipelines are laid at depths greater than five metres for lengths longer than 50 metres, concrete pipe jacking is always considered as an economic alternative to trenching. Benefits of Pipe Jacking and Auger Boring include but are not limited to: Safety during installation. Remote controlled, mechanical excavation Cost effectiveness Long drive lengths Minimal, gasketed flexible joints Structural soundness and Engineering integrity Watertight, maintenance free pipelines Continuous ground support Good flow characteristics Environmental benefits include: Reduces disruption and damage to services. Highway protected 90% less vehicle movements Less spoil Less quarried material The techniques require no second lining and is the Economic alternative to a disruptive, deep open cut. The laser guidance system allows for Real-time line and level checks, Maintains accuracy in difficult ground and allows remote operations.

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Method Statement Conventional Jacking System

Method of Construction: 1. 2. 3. 4. 5. 6. 7. 8. 9. Depending on soil conditions, this method may require deep-wells for dewatering purposes to be drilled at intervals along the span according to existing water level. A rectangular shaft is excavated of max. 6,700 x 5,000 mm or min. 5,700 x 3,500 mm to suit site conditions. A separate drawing will be submitted for each location. 200 mm thick concrete base will be provided at the bottom of each shaft. Pre-fabricated jacking rail is lowered into the shaft. A leading pipe steel sleeve is then lowered into the shaft and set on the rail. The leading pipe is then jacked into the soil by two hydraulic jacks, 300 tones each. Skilled miners then carry forward the face excavation until sufficient clearance is achieved. The jacking operation is then repeated. This action of excavation and jacking continues until the leading pipe is fully buried into the ground. When the leading pipe is fully buried the next section of the sleeve (each between 2,000 or 3,000 mm in length depending on the shaft size) is lowered and connected to the tail end of the leading pipe by a steel collar to give some flexibility to the directional operation.

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Method Statement Auger System

An Auger Boring Machine (ABM) is used to bore horizontally through soil or rock with a cutting head and auger. The majority of ABMs are used to install pipe casings under railroads, highways, airport runways, creeks or any area of ground that cannot be open cut or disturbed in any way. The machine bores through the earth with a cutting head and the jacking force is provided by the hydraulic thrust. The pipe casing and auger sections are added as the machine advances. Spoil is removed from the auger through the casing to a door located on the side of the machine. Method of Construction 1. 2. 3. 4. 5. 6. 7. 8. 9. Depending upon soil conditions this method may require a dewatering system if the existing water table level is above the drilling line. A rectangular shaft is excavated of min. 8,000 x 3,000 mm to suit site conditions. A separate drawing will be submitted for each location. This will be the starting pit. A 200 mm thick concrete base will be provided at the bottom of each shaft as a base for the Auger machine. The Auger machine is lowered into the shaft. A leading pipe steel sleeve with the required diameter is lowered with the crushing head into the shaft and set on the rail. The auguring process is then started until the leading pipe is fully buried into the ground. When the leading pipe is finished another sleeve will be lowered and welded to the end of the leading sleeve. The auguring process then continues until the sleeve is fully buried into the ground. Steps 6-7-8 are repeated until the sleeve reaches the exit pit. 13

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Equipment description
Auger Boring Machines (ABM) Main advantages: Large Deutz or CAT diesel engines for more power. Split design with easy connecting features. Heavy duty sub-frame for more stability. Pressure compensated load sensing system. Base can be used as pipe jacking unit. Steering head and grade indicator for accurate borings. All ABMs are equipped with: Rapid track and Rapid split. Auto hook roller engagement. Hydraulic clutch. Electronic anti-tilt switch. Pushbar engagement lights. Rugged, easy to use proportional controls.

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Several sizes of ABMs are readily available: Description Engine Engine Power Torque Clutch dia. Drive hex Hydraulics Cylinder ram stroke Ram thrust Length Width Heigth l/min Mm kN mm mm mm kW kNm Mm Unit ABM 36 CAT 3054C 80 166 343 4 144 (2) 914 2830 3658 1524 1676 ABM 48 CAT 3056C 117 271 343 4 144 (3) 914 4250 3962 1689 1676 ABM 60 CAT 3126B 154 280 365 (2 plate) 5 236 (4) 914 5660 3962 2134 1854 ABM 72 CAT 3126B 192 375 365 (2 plate) 5 236 (4) 914 5660 3962 2438 2184

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Completed Projects
The below reference lists represents only a small selection of trenchless projects undertaken by Copenhagen Contractors and/or its staff/subcontractors.

Location Kuwait

Client Council of MinistersSDFC Al- Wataniya Co. UmAlmadaram Co. National Contracting Co. Al- Khadda Int. & Cont. Co. Yusuf Al Sherhan Co. Combined Group Cont. Co. Ali Mohammad Al Ghanim Al Khateeb Industries Co.

Project name Installation of 400mm HDPE pipe Installation of UPVC pipe 1Way 6" as sleeve Installation of HDPE pipe 1Way x 8" as sleeve- MOT Project Installation of 6" x 4 way UPVC pipes as sleeve MEW Project Sleeve Installation of 22" Steel Pipe- KOC Project Installation of 4" x 1way UPVC pipe as sleeve Installation of Sleeve 8 Way x 6" HDPE Pipe Installation of 315mm UPVC Pipe Installation of 500mm Dia HDPE Pipe as sleeve- Bayan Palace Project. Installation of Sleeve- 2 Way x 120mm DWC- KOC Project Installation of 2,4" &6 HDPE PipesGreat Amman Water Supply Project Installation of 4 way 6" UPVC Pipe as sleeve

Meters 104

Method HDD

Year 2011

Kuwait

50

HDD

2011

Kuwait

102

HDD

2011

Kuwait

120

HDD

2011

Kuwait

33

HDD

2011

Kuwait

131

HDD

2011

Kuwait

53

HDD

2011

15

Kuwait

54

HDD

2011

Kuwait

180

HDD

2011

Kuwait

Arabian Const. Co. Al- Omaria Contracting Co. Bader Al Mulla & Brothers Co.W.L.L Greenline General Trading & Con. Co. KNETCO

429.6

HDD

2011

Jordan

5764

HDD

2011

Kuwait

120

HDD

2011

Kuwait

Sleeve Installation of 400mm & 1126 315mm HDPE PipeMOA Project

Installation of 2 Way UPVC Pipe 205

HDD

2011

Kuwait

HDD

2011

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Kuwait Afghanistan Kuwait Kuwait Kuwait

Al Omara USIDCINC Combined Group Cont. Co. KNETCO Al- Jahra Co.

Sleeve Installation of 4 Way 6& 8" HDPE Pipes Installation of Steel Sleeve 36" x 0,5" Installation of 9 Way x 110mm UPVC Pipes HDD Installation of 3 Way UPVC Pipes Installation of 315mm HDPE pipe - KOC Project Installation of 1800mm Dia Concrete Pipe- MPW Project Installation of 100/150mm (2 way) UPVC Pipe- MPW Project

1128 59.37 100 500 350

HDD Pipe Jacking HDD HDD HDD

2011 2011 2011 2011 2011

Kuwait

Burhan Int. Co. HOT Engineering & Construction

90

Pipe Jacking

2011

Kuwait

810

HDD

2011

Key Personnel
Senior Management:
Mr. Jeppe Handwerk, CEO, Owner, JEHA@CPHGROUP.COM Mr. Jeppe Handwerk established Copenhagen Contractors in 2004. During the following years the company has developed rapidly to encompass a wide variety of construction services, including design engineering, trenchless technology and building construction. Mr. Jeppe Handwerk served as a personal assistant for Kuwaiti Sheik Jasim al Homaizi and has in depth knowledge of the country. Mr. Brad Hester, Regional Director, Middle East/Africa, Copenhagen Group A/S, BRHE@CPHGROUP.COM Mr. Hester provides management direction to Copenhagen Group subsidiaries operating in Middle East region, with specific focus on HDD operations. He joined the company in 2009 as Director of Communications and Administration. Prior to that he served in numerous management positions within US government agencies, both in the United States and abroad. Mr. Jay Bryan Hicks. General Manager, JAHI@CPHCON.COM Mr. Jay Hicks has been training clients for Vermeer Middle East in the trenchless industry as the trenchless manager. Projects are numerous and include projects in Lebanon, UAE, Oman. Kuwait, Qatar, Sudan, Philippines, for all industries oil and gas, telecommunications, water, storm and sanitation drains, electrical, and fiber projects which includes all types of products and pipe. 16

Field Management:
Mr. Makhmoud Khader, Project Manager HDD, MAKH@CPHCON.COM Mahmoud Khader has a long record of successful Horizontal Directional Drilling projects in Kuwait. He is responsible for finding and offering the HDD jobs by meeting with the client to
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introduce the work in presenting HDD jobs (method of statement, previous and current projects, approvals and equipment details) and provide other technical clarification details to the clients. Furthermore, Mahmoud Khader is liable in finalizing the sub-contract agreement, purchase order or work order with the sub-contractor before commencing HDD jobs. On the job site he is responsible for ensuring that the work is properly done before and while commencing the major stages of HDD works. The job involves in procuring and meeting the supplier for HDD materials and equipment for negotiation and order finalization. Mr. John Salem, Project Manager Pipe Jacking and Microtunelling, JOSA@CPHCON.COM John Salem is a results-driven Project Manager with demonstrated expertise in managing, controlling and overseeing technical operators in pipe jacking and micro tunnelling. Responsibilities include supervision of site management team and ensuring that QA / QC, Health, & Safety and Environmental procedures are followed. John Salem has worked as Pipe Jacking project Manager on major Cross Country Pipeline Projects. Furthermore, he offers design support and estimating, planning, field supervision, quantity surveying, contracts administration, cost control, scheduling, budget administration, valuations, contractual assessment and variance analysis; Q.C. inspection on: - welding, coating, painting, building works, and civil works.

Admin and Logistics

Mr. Sivaprasad Ramanputty, Admin Manager, SIRA@CPHCON.COM Sivaprasad is in charge of Administration Department. His responsibilities include but are not limited to maintaining and keeping personnel file, Staff db, mobilization, R/R, Permits and passes, travel arrangements, visa, Salary conciliation, handling of petty cash, B/P, B/R, preparing invoices and other required official letters

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ill.: Copenhagen Contractors regional office, Farwaniya, Kuwait

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