SECTION 04100

TUNNELLING

PART 1: GENERAL

1.01 DESCRIPTION

1.01.1 Work Included: This section covers the requirements for constructing,
furnishing, delivery, placing, jointing, installing and finishing and all other work
as required for completion of a railway tunnel work.

1.01.2 Related Work Specified Elsewhere:

Section 03003 REINFORCING STEEL BAR

Section 03001 CONCRETE
Section 03101 STRUCTURAL STEEL
Section 02901 STEEL STRUCTURE
Section 02707 SEALANT

1.02 APPLICABLE CODES AND STANDARDS

The following codes and standards are intended to provide an acceptable

level of quality for materials and products. The Contractor may propose
alternative codes and standards provided they given an equivalent degree of
quality as the referenced codes and standards and are submitted for the
Employer review and approval in advance of their use.

ASTM American Society for Testing and Materials

A 82-90a Steel, Wire, Plain for Concrete Reinforcement

A 185 Steel Welded Wire Fabric, Plain, for Concrete Reinforcement
C 31-91 Test Method for Making and Curing Concrete Compressive
and Flexural Strength Test Specimens in the Field
C 33-82 Concrete Aggregates
C 39-81 Test Method for Compressive Strength of Cylindrical Concrete
Specimens,
C 117-90 Test Method for Materials Finer than No. 200 (75 mm) Sieve in
Mineral Aggregates by Washing
C 138-92 Test Method for Unit Weight, Yield, and Air Content
(Gravimetric) of Concrete
C 150-81 Portland Cement
C 172-90 Practice for Sampling Fresh Concrete
C 227 Alkaline Reactivity Test
C 231-91b Test Method for Air Content of Freshly Mixed Concrete by the
Pressure Method

C 233-93 Test Method for Air Entraining Admixtures for Concrete

C 260-77 Air Entraining Admixtures for Concrete
C 494-82 Type A Chemical Admixtures for Concrete

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 D 2125 Elastic Joint Filler
D 345-90 Test Method for Sampling Calcium Chloride for Roads and
Structural Application
D 4595-94 Tensile Strength and Elongation of Geotextile (Strip method)
D 4632-91 Tensile Strength and Elongation of Geotextile (Grab method)
D 4533 Tear Strength of Geotextile (Trapezoid method)
D 4751 Puncture Resistance

AASHTO American Association of State Highway and Transportation

Officials:

T26 Quality of Water to be used in Concrete

ACI American Concrete Institute

304 Recommended Practices for Measuring, Mixing, Transporting

and Placing Concrete
305 Hot Weather Concreting
308 Recommended Practice for Curing Concrete
309 Recommended Practice for Consolidation of Concrete
318-95 Building Code Requirement for Structural Concrete

AWS American Welding Society

D.1.1 Code of Practice of Welding

JIS Japanese Industrial Standards

A 1102 Grading of Aggregate

A 1103 Material passing 0.074 mm sieve
A 1104 Unit Weight of Concrete
A 1105 Organic Impurities
A 1108 Compressive Strength of Concrete
A 1109 Specific Gravity and Absorption
A 1111 Surface Moisture
A 1115 Sampling of Concrete
A 1121 Los-Angeles Abrasion
A 1122 Sodium Sulfate Soundness
A 5302 Reinforced Concrete Pipes
A 5751 Oil Based Caulking Compound for Buildings
A 5758 Polysulfide Sealing Compound for Buildings
A 6204 Air Entraining Agent
G 3112-85 High-yield deformed steel bar
G 3452-84 Carbon Steel Pipes or Ordinary Piping
G 3471-77 Corrugated Steel Pipes and Sections
R 5210 Portland Cement
K 6741-84 Unplasticized Polyvinyl Chloride Pipes
K 6773 PVC water-stop strips

1.03 QUALITY ASSURANCE

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 Comply with the applicable reference standards listed in Section 01201
QUALITY ASSURANCE/ CONTROL PROGRAMME and as specified
herein.

1.03.1 Before Construction

Before the construction of a new tunnel starts, safety surveillance shall be

carried as follows:

1. General:

In assessment of the influence of a new tunnel excavation to the existing

tunnel, deformation is infinitesimal, however, due consideration should be
given to train safety, investigation before construction, and daily
surveillance must be carried out to identify any unforeseen adverse
conditions during the construction period.

2. Cleaning of Existing Tunnel

Prior to the excavation of a new tunnel, the Contractor shall clean the
surface of the adjacent existing tunnel lining to detect deformation, cracks,
leakage of the tunnel. The Contractor shall prepare and submit a
deformation, cracks, leakage development diagram (drawing) to the
Engineer after detected observation and measurement of the location and
extent of the defective lining.

Until sixty (60) days before cleaning work commence, the Contractor shall
prepare and submit to the Engineer his detailed work plan comprising a
work schedule, work method, equipment to be used for approval.

For the cleaning, the Contractor shall take due precautions to prevent dust
accumulation inside the tunnel so as not to cause any hindrance to train
operations. Where any irregularities found on the surface of tunnel lining
during the cleaning, the Contractor shall immediately report to the
Engineer, and a remedial step shall be submitted to the Engineer for
approval.

Site lighting system for work sites and areas where observations and
measurements to be conducted shall comply with the requirements under
Clause Lighting for Underground Excavation, however, illumination shall
be tuned off during the passage of trains. Also, any facilities for the
cleaning of tunnel lining shall not interfere with the construction gauge.
3. Establishment of Control Standard

Lining strain measurement of the existing tunnel shall be taken to provide a

base control standard. The warning level comprises three steps, which
must be adapted as necessary to suit conditions on site.

The control standard values are as follows or as approved by the

Engineer:

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 Increase lining tensile stress: 0.5 MPa
Increase lining compressive stress: 2.0 MPa

Warning Level and Action Required

Warning Level Action Aim of Warning Level
I Confirm the measured value of allowable value
and notify the section in charge
II Increase the measuring and of allowable value
discuss countermeasures
III Stable the excavated area, stop Allowable value
new excavation and implement
countermeasures

1.03.2 During Construction

Observations and Measurements

During the construction of a new tunnel, the following various measurements

shall be carried out:

New Tunnel Existing Tunnel

Observation Observation of tunnel lining
Roof and wall displacement Roof and wall displacement
Ground settlement above a tunnel Strain on lining surface

1.03.3 After Construction

After completion of construction a new tunnel and removal all track inside an
existing tunnel, the steel fences shall be installed at two (2) entrances of the
existing tunnel. The steel fence shall have a height more than three (3) meters
for preventing people entering the tunnel without permission. The steel fence
shall have a door with a door lock from outside.

After completion of construction a new tunnel and both tunnel portal walls, the
painting and decoration of two (2) portal walls, and the installation of marks,
signs and signboards shall be carried out. The design of tunnel portals, marks
and signs shall be submitted to the Engineer for approval before carrying out.

1.03.4 Instrumentation

1. General

The Contractor shall furnish, install, maintain and take readings of

instruments for the measurement of ground movement, deformations of a
new tunnel and the deformation of the existing tunnel.

The instruments to be supplied, installed and maintained shall include, but

not limited to, electronic theodolite with an integrated coaxial
electro-optical distance-measuring system (total station), reflex targets,
disk load cells and surface strain gauge, together with all required

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 measuring equipment for reading the instruments.

All readings and measurements shall be taken by the Contractor to monitor

deformation of the new tunnel and the existing tunnel, and surrounding
ground in order to evaluate ground stability. The data shall be submitted to
the Engineer on a daily basis. The Engineer may direct adjustment of
support elements or modifications to the excavation plan on the basis of
the measured data.

Damaged or missing instruments shall be repaired or replaced by the

Contractor as soon as possible at no additional cost to the Employer.

The following various measurements shall be made to both of a new tunnel

and the existing tunnel to detect ground movements and underground
opening deformation:

2. Observation of both New Tunnel and Existing Tunnel

The Contractor shall observe conditions in the new tunnel and the existing
tunnel subject to the following provisions and/or others as instructed and
approved by the Engineer so as to assure safety in tunnels, and judge the
appropriateness of the construction method of support, and shall notify
these to the Engineer.

Observation and inspection shall be performed mainly around the new

tunnel face and the existing lining surface everyday, in order to grasp the
geotechnical conditions and inspect the effects of the support.

Observation and inspection results such as geotechnical conditions (rock

type, strike and dip of strata, fault seam, etc.), water leakage and support
deformation shall be arranged in figures and submitted to the Engineer
once a month for his review.

3. Measurement of Crown and Wall Displacement of the New Tunnel

The Contractor shall supply and install reflex targets on the new tunnel in
the pattern as shown or as directed by the Engineer. The reflex targets
shall be installed as soon as practicable after the tunnel has been
excavated and supported. Measurement shall be taken at intervals of 10 to
20 meters along the length of the tunnel, with five (5) measurement points
per section.

The measurement of crown and wall displacement is to monitor a change

in size of the tunnel, and the effectiveness of primary supports.

Reflex targets shall be securely attached shotcrete surface and located as

shown on drawings or directed by the Engineer. The total station shall be
used to measure the change in size of the tunnel, if any, occurring during
the period between excavation and construction.

Reflex targets shall be of approved non-corrosive material, and shall be

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 installed in accordance with the manufacturers instructions. Measuring
device shall be an electronic theodolite with an integrated coaxial
electro-optical distance-measuring system (Total Station) or other
equivalent device. The device to be used shall be proposed by the
Contractor and approved by the Engineer.

Measuring shall be made at once or twice daily until the heading has
advanced five times the tunnel width or otherwise directed by the Engineer
and weekly thereafter until the final underground excavation lining is
constructed.

4. Measurement of Ground Surface Settlement above the New Tunnel

The Contractor shall supply, a theodolite and levelling staffs for

measurement the ground surface settlement above the new tunnel at the
locations as shown on the Drawings or as directed by the Engineer.
Measurement shall be taken at intervals of 10 to 20 meters along the
length of the tunnel where the overburden depth less than two (2) times the
tunnel width, with at least five (5) measurement points per section. The
measurement section shall perpendicular to the tunnel advance direction.

The measurement of ground surface settlements is to monitor the effects

of tunnel excavation to the surrounding ground and structures.

Ground surface settlement measurement shall be made once daily before

and until the heading has advance three (3) times the tunnel width or as
directed by the Engineer and weekly thereafter until the final underground
excavation lining is constructed.

5. Measurement of Crown and Wall Displacement of the Existing Tunnel

The Contractor shall supply and install reflex targets on the existing tunnel
in the pattern as shown or as directed by the Engineer. Measurement shall
be taken at intervals of 10 to 20 meters along the length of the tunnel, with
seven (7) measurement points per section.

The measurement of crown and wall displacement is to monitor a change

in size of the tunnel induced by the excavation of the new tunnel.

Reflex targets shall be securely attached the existing lining surface prior
construction, and located as shown on drawings or directed by the
Engineer. The total station shall be used to measure the change in size of
the tunnel, if any, occurring during the period between excavation and
construction.

Reflex targets shall be of approved non-corrosive material, and shall be

installed in accordance with the manufacturers instructions. Measuring
device shall be an electronic theodolite with an integrated coaxial
electro-optical distance-measuring system (Total Station) or other
equivalent device. The device to be used shall be proposed by the
Contractor and approved by the Engineer.

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 Measuring shall be made at once or twice daily before the heading has
reached and until the heading has advanced three (3) times the tunnel
width or otherwise directed by the Engineer and weekly thereafter until the
final underground excavation lining is constructed.

6. Lining Strain Measurement

Measurement of the strain on the lining surface shall be carried out using
strain gauges or strain meters to monitor deformations of the existing lining
in order to evaluate the existing structural stability. The readings must be
checked regularly to ensure they are not over the allowable strain of the
lining material. Strain gauges shall be located at six (6) sections along the
line of the tunnel, with each section having three (3) gauges one at the
crown and the other two at each spring line.

The Contractor shall supply, install, measure and test surface strain meter
at specified locations in the existing tunnel as shown on the drawings or as
directed by the Engineer. Surface strain meter assemblies shall be
installed and tested in accordance with the manufacturers
recommendations.

The strain meters to be used shall be proposed by the Contractor and

approved by the Engineer.

1.04 SUBMITTALS

The Contractor shall submit the following documents/reports to the Engineer

for his review and approval.
1.04.1 Before Construction

(1) Detailed driving excavation and support plan. The excavation and
support plan may be revised by the Contractor during the progress of
work depending on physical and/or geological conditions encountered,
and the revised plan shall be submitted to the Engineer for approval. An
alternative plan may be submitted to the Engineer for his approval to
deal with a case in the failure of machinery to perform the required work.

(2) Structural design report based on the NATM, quantity calculation report,
design drawings and other necessary documents requested by the
Engineer.

(3) A complete description of the proposed equipment together with

documentation certifying the previous successful performance of the
equipment for the excavation of a tunnel of similar dimensions and
under similar geological conditions.

(4) An outline of the arrangement of machinery, equipment and facilities,

the system of excavation and hauling, and the progress schedule, in
due construction period and plan.

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 (5) Manufacturers specifications and installation/operation manuals and
instructions for the following products including laboratory test reports
and other data as required to show the compliance with specified
requirements:
- Structural steel (rock bolts), including certified copies of mill reports
covering chemical and physical properties;
- High strength bolts, including nuts and washers;
- Unfinished bolts and nuts;
- Structural steel primer paint; and
- Manufacturers data on other waterproofing membrane, geotextile
sheets, groundwater discharging hoses, and any other products and
materials deemed necessary for the work.

(6) 14 days prior to waterproofing work, a dewatering plan to discharge

groundwater leakage to outside the tunnel.

(7) Plans and detailed drawings of his temporary electric power supply
system, and temporary power distribution system.

1.04.2 During Construction

Re: Locations of face at the start and the end, survey results, details of rock
support installed, men and plant engaged, elapsed time for tunnel works and
unusual occurrences.

1. Daily reports covering the previous days work. This report shall include:
- Advance face;
- At start and end of rounds;
- Cross section and results of any observation and measurement made;
- Details of rock support installed, including rock bolts, shotcrete, steel
wire mesh reinforcement, steel support, concrete, and any other
material used;
- Number and classification of men and equipment engaged in each
operation;
- Elapsed time for each of the operations moving and set-up machine,
mucking, installation of supports, extending services (vent-line, water
lines, etc.), downtime delays;
- Total cycle time per round;
- Unusual occurrence, rock-falls, zones of instability, inflow of water,
occurrence of gas, and any accident sustained by workmen;
- Safety programs for the following;
- Rock-falls and displacement or settlement of any material surrounding
excavated hollow space;
- Flammable and toxic gases;
- Measurement Results implemented during construction.

1.05 PRODUCT HANDLING

1. Delivery and Storage:

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 Deliver all materials to the job site properly marked to identify the structure
for which it is intended.

2. Replacements:

In the event of damage, immediately make all repairs and replacements

necessary to the approval of the Engineer and at no additional cost.

1.06 TEMPORARY FACILITIES REQUIRED DURING CONSTRUCTION

1. Electric Power Supply and Distribution System:

The Contractor shall provide for his own use all necessary temporary
electrical equipment and materials such as diesel generator units,
transformers, switch-gear, protective equipment, meters and distribution
lines to surface and tunnel work sites and temporary buildings, including
staff quarters and labour camps. A concrete batching plant shall be
provided by the Contractor at locations adjacent to the work-site from
which concrete can be supplied without delay.

2. Water Supply System:

The Contractor will be permitted to take water from a well or from a local
river for his own use free of charge, however, shall at all times keep his use
of water to the minimum.

Temporary water supply system shall be operated and maintained by the

Contractor until Hand-Over certificate is issued or such a longer period as
may be directed by the Engineer.

The Contractors method of storage of water for construction purpose shall

be in accordance with the proposals as approved by the Engineer

3. Stockyard:

Ample areas shall be secured for stockpiling all products, equipment, tools
and materials required for tunnel works at location(s) readily accessible to
the work site. Watchmen shall be deployed throughout the project life to
prevent materials from pilferage.

4. Ventilation for Excavation:

The Contractor shall provide, install and maintain an appropriate

ventilation system for the tunnel works. The volume of required fresh air
shall be largely calculated. The following requirements shall apply to
construction sites.

The air breathed by persons in sites shall contain not less than 17 percent
of oxygen, and shall not contain a concentration of contaminants such as
gases, vapours and dust greater than safe for their health, having regard to

04100 - 9
 the combined effects of several contaminants.

The ventilation system shall be of a sufficient capacity to maintain an air

velocity of not less than 15 m/min. in the construction sites. Particular care
shall be taken to prevent the stagnation of air. The design of the ventilation
system shall provide for the type and size of all equipment suitable for the
site, as well as for the safe hygienic limits for exposure of workers to any
multiple toxic and objectionable gases that may occur in the site.

For each person working in the tunnel construction sites, a minimum

amount of 3 m3/min., of fresh air shall be provided.

Where diesel powered equipment is used in the site, the minimum quantity
of fresh air to be supplied shall be 3 m 3 /min., for each kW of power
employed within the site in addition to the requirements for personnel.

During excavation work, the ventilation system and the ventilation duct
shall be terminated not more than 30 meters from the face.

Use of internal combustion engines burning gasoline or liquefied

petroleum gases, propane, butane, propylene, butylenes shall be
expressly forbidden.

The Contractor shall submit, for approval, proof from prospective supplier
of diesel powered equipment for use inside a tunnel that the proposed
equipment conforms to the requirements of approved mining standards.

5. Lighting System:

The Contractor shall provide the following illumination in the construction

sites.

- Design illumination 100 lux

- Minimum measured illumination 60 lux

All power and lighting wires shall be adequate insulated, securely installed
and regularly checked for any damage.

The power and lighting wires shall be installed on one side of the tunnel.

6. Temporary Drainage System:

The Contractor shall supply, install, maintain and operate all necessary
diversion, pumping and other equipment to remove water from the site,
and discharge water to the outside.

Where water bearing seams (layers) or broken ground occur, a means of

relieving or controlling the flow of water into the tunnel, such as relief hoses,
shall be provided before installation of the outer lining shotcrete. Care
shall be taken to avoid plugging relief hose during shotcrete.

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7. Temporary Waste Water Treatment System:

The Contractor shall supply, install, maintain and operate all necessary
facilities and equipment to treat waste water from construction site. The
quality of waste water shall be monitored and treated to keep its quality
under Indonesian environmental standards before discharging to the
outside.

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 PART 2: PRODUCT

2.01 MATERIALS

1. Rolled Steel Bolts:

Comply with ASTM A36 except where otherwise applicable.

2. Reinforcing Bars:

Comply with ASTM A615 or JIS G 3112, SD 345.

3. Rock Bolts and Forepoling Bolts:

Rock bolts and filling-type forepoling bolts shall be 25 mm in nominal

diameter of high yield deformed steel bar complying with SD 345 of JIS G
3112-85, or equivalent quality as approved by the Engineer, and be of the
type as shown on the Drawings.

The grouting-type forepolling bolts shall have an inner diameter more

than 20 mm with urethane as a grouting material or equivalent quality
material as approved by the Engineer.

The rock bolts and forepoling bolts shall be threaded at one end and
pointed at the other to facilitate the placing operation. The sleeve
diameter shall be selected in accordance with the drill hole in order to
ensure the optimum filling of the hole.

The respective lengths of rock bolts or filling-type forepoling bolts and

their capacities are shown on the Drawings. The Engineer may direct
variations of the length and capacity depending on the site rock
conditions.

4. Cement:

Comply with the requirements in Section 03001 CONCRETE.

5. Aggregates:

Comply with the requirements in Section 03001 CONCRETE for both

coarse and fine aggregates.

6. Water:

Comply with the requirements in Section 03001 CONCRETE.

7. Admixtures:

Comply with the requirements in ASTM C260-86 or JIS A 6204 for air

04100 - 12
 entraining agents. The use of special cement or admixture shall be
approved by the Engineer even when used by the Contractor at his own
expense. The use of the admixture shall be proved harmless to the work
crew.

8. Shortcrete:

Generally, the quality of cement, coarse aggregates, fine aggregates and

water for shotcrete shall comply with the requirements in section 03001
CONCRETE.

In particularly, the fine aggregates shall be uniformly graded and have

the finest modulus in the range of 2.8~3.2. The maximum size of
aggregates shall be 10~15 mm. The grading of coarse and sand
aggregates shall be determined to satisfy the design criteria by the
Contractor and approved by the Engineer.

9. Steel Wire Mesh:

Comply with JIS 3551-80 Welded Wire Mesh of 5.0 mm in diameter with
150 mm opening, or equivalent quality as approved by the Engineer.

10. Steel Arch Support:

Comply with JIS 3101 Grade SS400 steel or equivalent quality as

approved, and to the shapes as shown on the Drawings.

11. Anchor Bolts:

Comply with ASTM A307, non-headed type with heavy hexagonal nuts
unless otherwise indicated.

12. High Strength Threaded Fasteners:

Comply with ASTM A325, heavy duty hexagonal structural bolts, heavy
duty hexagonal nuts, and hardened washers, shall be quenched and
tempered medium-carbon steel bolts, nuts and washers.

13. Metallic Non-shrink Grout:

Shall be non-corrosive, durable, non-shrink and shall be that upon which

design is based.

14. Waterproof Membrane:

Waterproof membrane shall be Ethylene Vinyl Acetate (EVA) polymer

sheet in the thickness of 0.8 mm bonded with Polypropylene or Polyester
non-woven permeable fabric in the thickness of 3 mm.

- EVA polymer shall comply with the requirements in JIS K6773 for

04100 - 13
 specific gravity, hardness, tensile strength, elongation, softening
temperature and chemical resistance, and with JIS K 6301 for tear
strength or equivalent quality as approved by the Engineer.

- Polypropylene or Polyester non-woven permeable fabric shall comply

with the requirements in JIS K 1096, for thickness, tensile strength,
elongation, tear strength, and with JIS AK 6301 for permeability or
equivalent quality as approved by the Engineer.

15. Drainage Filter Mat

Polyester, mono-filament, non-woven fabric: The filter mat shall comply

with the requirements in JIS 1096 for thickness, tensile strength,
elongation, tear strength, and with JIS 6301 for permeability or
equivalent quality as approved by the Engineer. (Considering the impact
at time of placing lining concrete, resistance strength shall be more than
75 kN/m2 at a compression ratio of 20%.)

16. Drain Pipes:

- Steel Drain Pipes and Fittings:

Comply with JIS G3452-84, Carbon Steel Pipes for Ordinary Piping,
or equivalent as approved.

- Corrugated Steel Pipe:

Comply with JIS-G3471-77, Corrugated Steel Pipes and Sections or

equivalent quality as approved.

- Reinforced Concrete Drain Pipe:

Comply with JIS A5302-84, Reinforced Concrete Pipes, or equivalent

quality as approved.

- PVC Drain Pipes:

Comply with JIS K6741, Unplasticized Polyvinyl Chloride Pipes or

equivalent quality as approved.

- HDPE (High Density Polyethylene) Drain Pipes:

Comply with JIS K6922-1, Plastics Polyethylene moulding and

extrusion materials, JIS K6761 and ASTM D2412 or equivalent
quality as approved.

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 PART 3: EXECUTION

3.01 CONSTRUCTION

3.01.1 Underground Excavation

1. General:

The tunnel excavation shall be carried out in accordance with the

principles of the New Austrian Tunnelling Method (NATM).

The term Underground excavation means all required excavation for

tunnel, refuge niches and other underground structures other than
open-cut excavation to establish tunnel.

The underground excavation shall be carried out by mechanical

excavation; drilling and blasting shall not be used because the adjacent
existing tunnel is most likely adversely affected.

2. Cross Section Design:

Underground excavation shall be carried out to the lines as shown on the

Drawings or as established by the Engineer.

The pay-line as shown on the Drawings are the outside limits to which
measurement for payment of excavation will be made, and measurement
for payment will in all cases be made to be the pay-line regardless of
whether the limits of the actual excavation fall inside or outside of pay-line.

3. Support Pattern Type:

The support patterns for supporting excavated ground along the tunnel
shall be classified into the following four types, as shown in the Drawings:

- Type A;

Type A pattern is for supporting the excavation through IIN class rock
which is generally stable. The support members are eight (8) rock bolts
and min. 100-mm thickness of shotcrete with steel wire mesh. Rock
bolts shall be installed at the interval of 1.5 m in the longitudinal
direction.

- Type B;

Type B pattern is for supporting the excavation through I N-2 class rock.
The support members are nine (9) rock bolts, H125-type steel supports
at upper section, and min. 125-mm thickness of shotcrete with steel
wire mesh. Rock bolts, and steel supports shall be installed at the
interval of 1.2 m in the longitudinal direction.

- Type C;

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 Type C pattern is for supporting the excavation through I N-1 class rock,
or the section which has an overburden depth less than 2 times of
tunnel width. The support members are thirteen (13) rock bolts,
H125-type steel supports at upper and lower sections, and min.
150-mm thickness of shotcrete with steel wire mesh. Rock bolts, and
steel supports shall be installed at the interval of 1.0 m in the
longitudinal direction.

- Type D;

Type D pattern is for support the excavation through IS class rock or

tunnel portals. The support members are eight (8) rock bolts,
seventeen (17) forepoling bolts, H150-type steel supports at upper and
lower sections, and min. 150-mm thickness of shotcrete with steel wire
mesh. Rock bolts, and steel supports shall be installed at the interval of
1.0 m in the longitudinal direction.

4. Determination of Support Pattern Type:

Initial determination of the support pattern type encountered shall be

agreed between the Engineer and the Contractor according to the
conditions exposed in the freshly excavated opening.

A change in support pattern type shall be determined only if there is a

significant change in the types and quantities of the primary support
means required.

The Contractor shall regularly monitor support elements with instruments

and observations of the tunnel. The results of measurements shall be
made available and reported to the Engineer.

Any additional support materials taken by the Contractor other than

support materials shown on the Drawings or stated on the Bill of Quantities,
or agreed to or ordered by the Engineer shall be at the expense of the
Contractor.

5. Excavation Procedures:

Bench cut method shall be the typical excavation method for tunnel
excavation, and other proper excavation procedures shall be adopted to
suit the designed cross section to be accommodated the material to be
excavated and the conditions to be encountered.

During the excavation work, the Contractor shall, at his full responsibility,
maintain the lines shown on the Drawings by accurate surveying as
approved by the Engineer.

All excavation shall be carefully performed. The Contractor shall use

mechanical excavation techniques which will produce a smooth final
profile, a minimum of over-break and a minimum of stressing or fracturing

04100 - 16
 of rock.

At least 14 days before the work, the Contractor shall submit his detailed
mechanical excavation plan to the Engineer for approval.

All plans shall be subject to review by the Engineer. This review shall not
relieve the Contractor of his complete responsibility for methods, means,
procedures, accuracy, adequacy and safety of the mechanical excavation,
exercising proper supervision and field judgement, and producing the
design lines specified herein.

Any and all over-excavation performed by the Contractor for any purpose
or reason, except as may be directed, and due to the fault of the Contractor,
shall be at the expense of the Contractor. The Engineer may direct that all
such over-excavation shall be backfilled with shotcrete or concrete and the
cost of furnishing and placing the backfill shall be at the expense of the
Contractor.

6. Mucking:

All excavated soil and rock shall be disposed of with reasonable measures
or stockpiled in spoil banks as directed by the Engineer. During mucking,
muck-pile shall be wetted down with fine water sprays.

3.01.2 Primary Supports of Underground Excavations

1. General:

The Contractor shall furnish and install primary support for the
underground excavations as shown on the drawings or as directed by the
Engineer.

Primary support shall consist of the use of individual elements such as

shotcrete, steel wire mesh, grouted rock bolts, forepoling bolts, steel
supports and temporary supports, or combination thereof.

Measures will be related to chosen heading procedure, the rock type and
the results of crown and wall displacement measurements. The routine
installation of support elements in conjunction with excavation work is an
integral part of the NATM, with the ability to vary the support elements to
suit the exposed ground conditions.

The support elements described elsewhere and shown on the drawings for
any particular rock type are to be taken as typical and may be varied in
quantity and/or thickness as approved or directed by the Engineer to suit
the actual exposed ground conditions.

Primary support shall be installed immediately after completion of each

round of the tunnel excavation.

Where ground condition so warrant, the Engineer may direct the

04100 - 17
 Contractor to install support up to the face from muck-pile immediately
after excavation, and the Contractor shall not be entitled to any additional
payment for comply with such directions.

The Contractor shall maintain on the site an adequate supply of the

various support elements for the excavation of the work, and delay due to
lack of support elements will give the Contractor any rights to claim for
extension of completion dates.

2. Grouted rock bolts and forepoling bolts:

- General;

The Contractor shall furnish and install grouted rock bolts and
forepoling bolts in underground excavation as shown on the Drawings
or as directed by the Engineer. Rock bolts and forepolling bolts,
complete with all required accessories, including bearing plates, nuts,
washers, filling and grouting materials, shall be supplied by the
Contractor. The use of chemical resin anchors or cement grout
anchors shall be subject to approval by the Engineer.

The Contractor shall plan his equipment and operations for

underground excavation so that routine installation of rock bolts can be
carried out as excavation proceeds at the face.

The installation of grouted rock bolts and forepoling bolts shall be under
the direct supervision of personnel having at least two (2) years
experience in rock bolting works. The Contractor shall keep on site,
ready for immediate use, a sufficient stock of rock bolts and
accessories to avoid delay to the work.

- Installation pattern;

Rock bolts and forepoling bolts shall be installed in patterns in

underground excavation in order to form structural entities. The
required patterns in which the rock bolts and forepoling bolts shall be
installed as shown on the Drawings, or as directed by the Engineer.

The rock bolts and forepoling bolts, and methods of installation in

underground excavation, including the drill hole diameter and length,
and the details of the equipment necessary to drill the hole, to clean out
the drilled hole, to install and grout the rock bolts in the hole and test the
anchorage, shall be in accordance with the manufacturers instructions,
manual and subject to approval by the Engineer.

When rock bolt or forepoling bolt support is directed, the hole shall be
drilled and cleaned out, and the rock bolts and forepoling bolts shall
then be installed without delay. The forepoling bolts shall be installed
before the next excavation.

Standard percussion drilling equipment may be used for drilling rock

04100 - 18
 bolt and forepoling bolt holes. The holes shall be drilled to the size and
depth recommended by the manufacturers instructions, manual and
approved by the Engineer.

- Testing of rock bolt installations;

The Engineer will select rock bolts for pullout tests, and the Contractor
shall test such bolts using a calibrated hydraulic jack. All tests shall be
witnessed by the Engineer. The Contractor shall provide and maintain
the tools, equipment and labour to perform these tests. As an average,
one bolt in 200 of the rock bolts installed shall be tested. The tests
should be performed after installing a rock bolt more than 3 days, at
tunnel crown or tunnel spring line or other positions which are
instructed by the Engineer.

The pullout strength shall be at a level equivalent to the yield strength

of the rock bolt (usually, yield strength of the thread portion). The rock
bolt could be judged to be adequate, if it exhibits about 80% of the
stipulated pullout strength. Any rock bolt which does not meet the test
will be rejected. The decision whether to replace defective rock bolts
will be made by the Engineer.

Prior to installing the bolts, the rock surface shall be prepared for
accepting the washer plates. Such prepared bearing surfaces shall be
normal to the axis of the hole and if necessary tapered plates or
washers shall be used.

Ungrouted rock bolts shall be installed using special tools as

recommended by the manufacturer. They shall be tensioned, using a
torque wrench, to a value as directed and in accordance with the
recommendations of the manufacturer.

When requested by the Engineer, the Contractor shall check the

installed bolts by pullout test. In case of a significant load decrease, the
bolts shall be re-tensioned to the satisfaction of the Engineer.

Where necessary, rock bolts may be used in conjunction with small

steel beams, steel plates, lagging or wire netting. The wire net shall be
of welded wire type in accordance with approved standards.

Each permanent rock bolts shall be provided with two independent forms
of protection against corrosion at all points of the entire surface of the
completed installation. The Contractor shall submit his proposal for
corrosion protection to the Engineer for approval.

To carry out the excavation work without delay, the Contractor shall always
have on stock sufficient quantities of rock bolts, of various types and length,
wire mesh and other accessories.

3. Shotcrete:

04100 - 19
- General;

The Contractor shall apply shotcrete to crown and wall of underground

excavation as shown on the Drawings or as directed by the Engineer.
Shotcrete shall mean concrete with or without admixture,
pneumatically applied at high velocity onto a prepared rock surface.
Both dry-process and wet-process methods shall be used.

Where shotcrete support is required, the Contractor shall apply

shotcrete to give a thickness shown on the Drawings or as directed by
the Engineer. The thickness required on the Drawings and
Specifications are the minimum thickness of the shotcrete layer as
measured over rock points. Successive layers shall be placed to
achieve the required support thickness.

- Design Strength;

The compressive strength shall be satisfied as follows.

3 hours: 1.5 MPa minimum
24 hours: 8.0 MPa minimum
28 days: 18.0 MPa minimum

- Mix Proportions;

The Contractor shall propose the mix proportion of shotcrete for the
approval of the Engineer together with the data enough for the
Engineer to make judgement. And if directed, the adjustment of mix
proportion shall be proposed by the Contractor.

The table below gives the reference values for mix proportions of
shotcrete.

Item Unit Standard value

Max. size of aggregates mm 10~15
Finest modulus of sand 2.8~3.2
Slump : pumping type cm 82
air type cm 142
Water-cement ratio (W/C) % 50~60
Sand-aggregate ratio (s/a) % 60~65
Cement content (C) kg/m3 360
Air content % 4.51.5

- Equipment;

Water supply system:

Shall consist of a positive displacement pump capable of supplying

water through a regulating vale with non-pulsating flow and
accurately controllable by nozzle man, in sufficient amount and at a

04100 - 20
 pressure above operating air pressure recommended by the
manufacturer of the shotcrete delivery machine. A suitable water
pressure and flow meter shall be fitted to the water supply system.

Air supply system:

Shall be capable of supplying the shotcrete machine and hose with

air at the pressures and volumes recommended by the
manufacturer of the machine. A suitable air pressure meter shall be
fitted to the air supply system adjacent to the shotcrete machine.
No air supply systems shall be used that delivers air contaminated
by oil or that is incapable of maintaining constant pressure.

Shotcrete machine:

Shall have an acceptable performance record in applying coarse

aggregate shotcrete as specified herein. The shotcrete machine
shall be capable of introducing material to the delivery hose at a
uniform rate, with ejection from the nozzle at velocities that will
afford adherence of material to the surface to be treated with a
minimum rebound and maximum adherence and density.

The entire system shall be so arranged that the nozzle man may
use air and water in any combination to prepare surfaces on which
shotcrete will be applied.

Equipment, including protective equipment for the nozzle man shall

be provided to allow application of shotcrete to surface at an
approximate distance of 1 meter from the nozzle.

- Field Trials;

Field trials shall be made to demonstrate the capability of the

equipment, workmanship and materials under field conditions at least
14 days prior to the actual application of shotcrete in underground or
surface works.

The field application of each mix selected for field trial shall be made on
overhead horizontal and/or vertical test panels to simulate construction
conditions.

Fifty (50) to Sixty (60) mm diameter cores shall be taken from each
overhead horizontal and each vertical test panel. With the exception of
cores for one-day strength, all cores shall be taken one day before
testing.

Cores shall have a length as 2.0 times of a diameter and shall be tested
for their one and 28-day strength. The average strength of all cores as
a minimum shall be as follows:

Compressive strength 1 day 8 MPa minimum

04100 - 21
 Compressive strength 28 days 18 MPa minimum

The minimum strength obtained by testing shall be not less than 80% of
the above-mentioned values. Mixes failing to meet the above
requirements will be rejected. All phases of field trail work shall be
performed in the presence of the Engineer.

The Engineer will inform the Contractor in writing, of his acceptance of

mixes which meet the requirements of this Section. No shotcrete mix
shall be used in field trials if the mix has not been approved by the
Engineer.

The actual proportions of ingredients determined and approved by the

Engineer, on the basis of trial mixes and field trials, shall be used in the
actual application of shotcrete and shall not be varied without the
written approval of the Engineer.

- Workmanship;

The work shall be performed by experienced workmen.

Nozzle men shall have had previous satisfactory experience in the

application of coarse aggregate shotcrete in underground projects or
shall work under the immediate supervision of a foreman or instructor
with such experience.

Each nozzle man shall demonstrate, to the satisfaction of the Engineer,

acceptable proficiency in the application of shotcrete in field trials to
vertical and overhead test panels before commencing shotcrete work
in underground.

- Preparation;

Wherever shotcrete is required, the Contractor shall clean and prepare

the surfaces to receive the coating. Loose or shattered rock debris, soil
or other loose material and any oil film or otherwise objectionable
substances shall be removed from the surfaces. After the loose
material has been removed, the surface shall be thoroughly cleaned
with water under pressure and/or compressed air. Any remaining
water shall be blown off by compressed air.

Any seepage water emerging locally shall be dealt with by local sealing
with drainage measures.

- Application;

No shotcrete shall be applied to the work until the quality of

workmanship and the compressive strength of the shotcrete, as
determined from test panels, is approved.

After the specified preparation has been carried out and immediately

04100 - 22
before shotcreting, the surface shall, where required, be thoroughly
cleaned and wetted with a strong blast of air and water. Application
shall commence at the bottom of vertical and near vertical surface and
each layer of shotcrete shall be built up by marking several passes of
the nozzle over the working area.

Shotcrete shall be built up in successive layers such that sagging and

bleeding does not occur. Wherever practicable, rock surfaces shall be
rendered free of water flowing over or seeping through the surface to
be shotcreted immediately before the shotcrete is applied.

The thickness of the shotcrete to be applied shall be as shown on the

Drawings, or as approved or directed by the Engineer. During the
application, the thickness shall be determined by an approved means.

The distance of the nozzle from the work shall be between 600 mm and
1,500 mm and the nozzle shall generally be held perpendicular to the
application surface. The shotcrete shall emerge from the nozzle in a
steady uninterrupted flow. When the flow becomes intermittent from
any cause, the nozzle operator shall direct it away from the work until it
again become uniform.

All rebound and other loose material shall be removed by air jets or
approved means from the surface of each layer as work proceeds.

During application of the shotcrete, any remaining water flowing over or

seeping through the surfaces to which the shotcrete is to be applied
shall be diverted by the use of panning, pipes felt strips or other
approved means. Where directed, formed holes of 75 mm diameter
PVC or PE pipe outlets shall be provided in the shotcrete, as directed,
to relieve water pressure on the shotcrete.

Layer thickness shall mainly be governed by the requirements that the

material shall not slump or sag and is dependent on factors such as
position of reinforcement, plan of application, mix design, constituents
and use of admixtures. Where thick layers are to be applied it is
important that the leading edge be maintained at a slope. Where
successive layers of shotcrete are necessary to achieve the required
overall thickness, each layer of shotcrete shall first be allowed to stiffen,
all laitance and loose material remove and the surface wetted using a
strong blast of air and water before the next layer of shotcrete is placed.

The position of contraction joints and the method of forming shall be

subject to approval by the Engineer. Contraction joints shall be formed
at right angles to the face for at least half the depth of the layer being
placed. Construction joints shall be tapered at approximately 30
degrees unless otherwise directed. The entire joint shall be thoroughly
cleaned and wetted before placing adjacent shotcrete. Reinforcement
shall be cleaned up any previously deposited hardened material which
might prevent a proper bond or encasement.

04100 - 23
 A proportion of shotcrete will be rebound. Such rebound shotcrete
shall not be reused but shall be removed to disposal at the expense of
the Contractor. All rebound shotcrete shall be removed from the Works
and disposed of by the Contractor as part of the work under this
Clause.

The Contractor shall ensure that the shotcrete application operation is

adequately lit by floodlight and he shall provide adequate ventilation
facilities and take such other measures as necessary for safety of his
workmen, including provision of face protection of nozzle men.

- Repair;

Shotcrete which lacks uniformity, exhibits segregation, honeycombing,

lamination, showing cracking shall be regarded as defective shotcrete.
The Engineer may order removal of defective shotcrete and order its
replacement with acceptable shotcrete, or other remedial measures
without additional cost to the Employer. Shotcrete shall not be placed
over a defective shotcrete layer until the required remedial measures
have been taken. Any remedial measures directed by the Engineer to
correct defective shotcrete shall be at the expense of the Contractor.

4. Steel Wire Mesh:

The Contractor shall submit his procedure for the fixing of steel wire mesh
for approval prior to beginning of installation. Short bolt (surface anchors),
rock pins driven into joints or shotcrete onto a previous layer, shoot-in
studs, or any combination of these means are acceptable provided the
steel wire mesh closely follows the geometry of the excavation. Under no
circumstances shall space between the underlying surface and the steel
wire mesh is more than 15 cm.

The Contractor shall furnish and place steel wire mesh on the surface of
underground excavation in conjunction with the installation of rock bolts or
steel supports. Steel wire mesh shall be properly placed and anchored to
prevent possible rock falls. A minimum overlap of 15 cm shall be used at
joints.

5. Steel Support:

- General;

The Contractor shall furnish and install permanent steel support to

support the crown and side walls of underground excavation as shown
on the Drawing or as directed by the Engineer.

Permanent steel supports completed with all bolts, tie rods, footplates
and other accessories required for assembly of the supports and
supporting them in place until the lining concrete is placed.

Temporary steel supports that are not required to be in place as the

04100 - 24
 permanent work shall be removed unless such removal is determined
impracticable by the Engineer.

Type and size of the steel supports, its miscellaneous details, location
and spacing shall be submitted to the Engineer for his approval. The
clear distance between the flanges of the installed supports shall not be
less than 30 cm unless otherwise approved by the Engineer.

- Installation;

The steel support shall be installed to the proper lines and grades and
shall be maintained by the Contractor in the proper condition and
alignment until the lining concrete is placed about them. The Contractor
shall securely brace the supports with tie rods, and shall use the
minimum practicable amount of timber blocking and wedges between
the steel arch supports and the rock. Any steel supports installed
improperly or damaged by the Contractors operation shall be adjusted
or repaired or replaced to the satisfaction of the Engineer within 24
hours after notification by the Engineer.

Temporary timber collar braces shall be furnished and installed by the

Contractor where required to install the steel supports, and shall be
removed before lining concrete unless such removal is determined
impracticable by the Engineer. At such time, any redundant timber
blocking and wedges shall also be removed.

The Contractor may, to facilitate his operation, place permanent steel

support at a greater distance from the inside finishing surface of
concrete lining than that shown on the drawings or specified by the
Engineer, provided that any increase in quantity of steel supports and
any excavation and concrete lining outside the pay-line as shown on
the Drawings, required thereby shall be at the expense of the
Contractor.

Permanent steel supports required for the section shall be in

accordance with designs submitted by the Contractor and approved by
the Engineer.

- Steel Lagging;

Steel lagging shall be plain or profile sheet of at least 5-mm thickness.

The steel shall conform to JIS 5528.

The lagging shall be placed between the flanges of steel supports and
fixed in position by wedging off of the front flange of the steel support
using hardwood timber wedges. The space between the lagging and
the excavated profile may be filled with concrete or discrete timber
packing.

- Temporary Support;

04100 - 25
 Temporary timber or steel supports including bracing shall be provided
where necessary until permanent steel arch support is installed, and
also for support of temporary excavations such as tunnel drifts, and as
may be otherwise required for construction purposes. Supports that
are not required to remain in place can safely be removed, may be
removed subject to the direction or agreement of the Engineer.
Support in good condition may be reused. Suitable temporary timber,
may be used to support the crown and side walls of the concrete lining,
is placed and every precaution shall be exercised as to timing and
extent of removal to prevent accidents.

Temporary steel supports shall conform to the requirements specified

herein before permanent steel arch supports or other requirements
approved by the Engineer. When the Contractors method for removal
of such temporary timbering is unsuitable as determined by the
Engineer, the Engineer may instruct the Contractor to suspend the
work and the Contractor shall follow the directions of the Engineer. An
ample supply of temporary timbering shall be stocked on site to meet
any emergency demand for temporary support.

- Tunnel Markers;

The Contractor shall maintain chainages marked on the tunnel walls

every 50 meters. The markings shall be clear and painted in an
approved colour and shall not lag more than 100 meters from the face.

3.01.3 Lining, Invert, Refuge Niche and Other Concrete Structures

Placing of concrete for lining of the tunnel and refuge niches shall be carried
out using sets of travelling steel form. The number and length of the steel form
elements will be determined by the required daily progress and the minimum
formwork stripping time.

Stripping shall not be permitted until the concrete has reached at least 2.0
Mpa cylinder compressive strength and not less than eighteen (18) hours or
as approved by the Engineer after the completion of concreting of that
element.

Equipment for concrete transport and placing shall be of such a design and
capacity as to guarantee the continuous poring of the lining. The placing
system shall provide the optimum filling of the arch vertex.

Placing of lining concrete shall be carried out after waterproofing has been
installed.

In the event of equipment breakdown, or if for any reason continuous placing

is interrupted, the Contractor shall thoroughly consolidate the concrete at such
joints to a uniform and stable slope while the concrete is plastic. If cold joints
occur, the concrete at the surface of such joints shall be cleaned as required
for construction joint as specified in Section 03001 Concrete, and
moisturized before being covered with fresh mortar and concrete.

04100 - 26
 The method of concreting shall be approved by the Engineer. Concrete shall
be consolidated by immersion vibrators.

Concreting wok for roadbed concrete, centre passage, cable box and portal
walls shall be carried out complying with the requirements as specified in
Section 03001 Concrete. The dimensions of concrete shall be as shown on
the drawings.

There are two types of refugee niches: medium and small types. The refuge
niches shall be constructed at both sides of a tunnel as the staggered
arrangement. The small-type refuge niches shall be constructed at the
interval of 20 meters from the other tunnel side. While the medium-type
refuge niches shall be constructed at the interval of 100 meters from the other
tunnel side. The size, shape and location of refuge niches shall be
constructed as shown in the Drawings.

The minimum compressive strength of each element at age 28 days shall be

as follows or as approved by the Engineer:

Lining concrete 21 MPa minimum

Invert concrete 21 MPa minimum
Roadbed concrete 24 MPa minimum
Centre passage concrete 21 MPa minimum
Cable box concrete 21 MPa minimum
Portal walls concrete 24 MPa minimum

Repair: Concrete with wide cracks shall be repaired by the Contractor without
additional cost to the Employer. The Contractor shall prepare and submit the
drawings of cracks with their length and width, and their repair method to the
Engineer for approval. Any remedial measures directed by the Engineer to
correct concrete cracks shall be at the expense of the Contractor.

3.01.4 Waterproofing:

1. Surface Treatment:

Prior to installation, the unevenness of ground surface shall be smoothed

with shotcrete to prevent any damage on waterproof sheets.

Except for nuts, all heads of rock bolt shall be trimmed and covered with
mortar or thick felt material.

2. Installation:

Waterproof sheets shall be installed between the primary and secondary

linings (lining concrete) as recommended by the manufacturers
specification at locations as shown on the Drawings or as directed by the
Engineer.

3.01.5 Drainage System:

04100 - 27
1. Centre Drainage and Cross Drainage;

Reinforced concrete centre drainage and cross drainage pipes shall be

provided at locations as shown on the Drawings.

Base concrete shall be placed at locations where ditches excavated and

concrete pipe shall be securely installed. Pipe joints shall be secured with
mortar. Aggregates for backfill shall be of less than 40 mm in diameter.
The surface of backfilled aggregates shall be covered with waterproof
sheet to prevent clogging of the pipe due to concrete works.

2. Longitudinal Drainage behind Lining Concrete;

Longitudinal drainage behind lining shall be installed at the locations as

shown on the Drawings. Care shall be exercised for joints with waterproof
sheets.

3. Drainage Pit

Catch basins shall be provided at locations as shown on the drawings or

as directed by the Engineer. All drainage pipes shall be carefully joined
with catch basins to prevent any leakage. All concreting work for catch
basin shall comply with Section 03001 CONCRETE.

4. Joints and Sealing:

- Construction Joints

Concreting shall be carried out continuously up to construction joints,

the position and arrangement of which shall be as shown on the
Drawings or as approved by the Engineer. The Contractor shall submit
a drawing with full details of proposed joints (in addition to those shown
on the Drawings and specified by the Engineer) including the shuttering
and reinforcement details, in sufficient time to enable the Engineer to
consider the implication of the proposal.

Construction joints in highly stressed parts and in water-retaining

structures shall be avoided as far as possible.

- Contraction/Expansion joints

The Contractor shall provide contraction/expansion joints as shown on

the Drawings or elsewhere as directed by the Engineer. The joint
material will consist of a layer of bituminous coating on the face of the
first concrete.

5. Formwork

Formwork shall be in accordance with Section 03001 CONCRETE. Until

removed, the formwork for the lining concrete and invert concrete shall be

04100 - 28
left for the periods not less than the following times or as approved by the
Engineer.
Lining Concrete 15 hours
Invert Concrete 12 hours

- END OF SECTION

04100 - 29