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TECHNICAL INSTRUCTION
FOR CONSTRUCTION OF CABLE DUCT-
WAY THROUGH HDD METHOD
The document entitled Technical Instruction for Construction of Civil Work through HDD Method has been
prepared, reviewed and approved by the following committee:
REVISION RECORD
DISTRIBUTION LIST
TM JKH CONTRACTOR
AGM Regional Network Maintenance &
TABLE OF CONTENT
1 OBJECTIVE ........................................................................................................................................ 7
2 SCOPE ............................................................................................................................................... 7
3 REFERENCES.................................................................................................................................... 7
4 DEFINITION AND ABBREVIATION..................................................................................................... 7
5 BACKGROUND .................................................................................................................................. 8
6 PROCEDURE ..................................................................................................................................... 8
6.1 SPECIFICATION OF HDD W ORK ................................................................................................... 8
6.2 PLANNING FOR HDD W ORK .......................................................................................................10
6.3 SITE SURVEY AND UTILITIES MAPPING.........................................................................................11
6.4 PILOT HOLE D RILLING ...............................................................................................................12
6.5 REAMING .................................................................................................................................14
6.6 LAYING OF HDPE D UCT..............................................................................................................15
6.7 JOINTING OF HDPE TO EXISTING MANHOLE .................................................................................16
6.8 BACKFILLING OF EXCAVATED AREA .............................................................................................17
6.9 REINSTATEMENT OF EXCAVATED AREA .......................................................................................19
7 TESTING AND INSPECTION .............................................................................................................20
7.1 MANDREL TEST ........................................................................................................................20
8 MATERIAL .........................................................................................................................................20
9 SAFETY AND PRECAUTION .............................................................................................................21
9.1 W ORKING AT THE R OAD SIDE .....................................................................................................21
9.2 W ORKSITE AREA .......................................................................................................................21
9.3 HANDLING OF HDPE DUCT ........................................................................................................21
9.4 DRILLING FLUID ........................................................................................................................22
10 DOCUMENTATION............................................................................................................................24
11 ACKNOWLEDGEMENT .....................................................................................................................24
LIST OF FIGURE
LIST OF TABLE
Table 6-1 : Depth of HDD Work Specification............................................................................................. 8
Table 6-2 : Common Areas for HDD Work ................................................................................................11
Table 6-3 : Relevant Agencies for HDD Work Permission .........................................................................11
Table 6-4 : The Size of Reamer for HDD Work..........................................................................................14
Table 9-1 : The Minimum Clearance from High Voltage Cable ..................................................................22
Table 12-1 : Acknowledgement ...................................................................................................................24
1 OBJECTIVE
The objective of this document is to provide Technical Instruction for construction of cable duct-
way through HDD method for telecommunication infrastructure.
2 SCOPE
The scope of this document covers the followings:
3 REFERENCES
Term Meaning
PU Plant Unit
TM SPV TM Supervisor
5 BACKGROUND
5.1 Conventional open-cut trenching on the road and grass has been used extensively in TM civil
work infrastructures to provide duct-way for cable laying. However this method requires
massive excavation work, expensive milling cost and may not be suitable in areas with limited
road shoulder or carriageway high traffic.
5.2 HDD is a trenchless method of installing duct in the ground at variable angles using a guidable
drill head. The drill path may be straight or gradually curved, and the direction of the drilling
head can be adjusted at any stage during the initial pilot bore to steer around obstacles or
under highways, rivers or railways
5.3 The method is suitable for variety of soil conditions and duct diameters.
6 PROCEDURE
This section will explain the specification of HDD and technical instruction for construction of
new civil work through HDD work.
The depth of the HDD pipe cross is correlated with the bore diameter. Table 6-1 summarizes
the minimum allowable depths and the setback for HDD work:
i. The penetration angle for both entry and exit shall be between 10 and 18 degree.
ii. Setback is the distance required from ground penetration to target depth or from target
depth to the ground level.
iii. The distance between the entry and exit point of HDPE conduits to the existing manhole
shall be within 2 to 3 meter.
iv. AND Project Manager must determine the specification of HDD work by determining the
depth of the HDD work. The minimum depth must not less than 1 meter below the
finished road or ground surface. Figure 6-1 illustrates the HDD cross sectional layout.
v. For construction of duct-way which is more than 16, the HDD method is not
recommended and no PU is available in the TM contract for the work.
This step includes selection of the route, depth of excavation and determining the tools and
material needed for the work. The planning shall be done with care therefore the planned
layout will achieve the objective and able to avoid any changes after excavation work
starts. The important steps in the planning are as follows:
i. Determine the number, size of the duct-way and length of the construction. Careful
study shall be done to ensure the number of duct-way for cable laying shall meet
the purpose and optimizing the cost.
ii. Select the shortest routes and location where the pipeline can be constructed in
one continuous length.
iii. Since HDD work is very expensive, AND Project Manager must consider future
requirement of the duct-way by determining the suitable number of ways during
initial planning. This is to ensure that the HDD project is cost effective, cater for
future expansion and provide long-term benefit to TM.
i. HDD works may not be suitable for certain types of areas, thus there is a
responsibility for AND Project Manager to identify the suitable areas, ground
conditions, surrounding utilities and to consider safety and environmental issues
before work starts.
ii. Choose the route that will not damage valuable plant such as trees, landscape,
carriageway or structure. Identify the type of soil. Sandy soil, loose soil, wet and
mucky soil will make the excavation process difficult and dangerous.
iii. Determine the starting point and the end point of HDD work.
iv. Table 6-2 shows the common areas for HDD work. Other than this area shall be
treated case by case basis.
1 Crossing River
2 Crossing Highway
3 Crossing Railway
JKH is required to obtain approval from relevant authorities before start work. Table 6-3
below shows examples of relevant agencies/authorities for application of HDD work
permission.
Site Survey and utilities mapping is compulsory and shall be done before excavation
works start. The scanning of the proposed route is required to avoid unnecessary
damages to other underground utilities. Excavation work will only commence upon
confirmation on the underground accessibility; otherwise the route shall be diverted.
i. The construction site must be prepared before the main drilling operation. A drilling
rig must be set up at the proper location and drilling hole (starting hole) is
excavated as shown in figure 6-3. AND Project Manager must also determine the
location of receiving hole where the bore head will make an exit.
ii. Generators, pumps, storages and safety materials must be ready at this stage.
iii. HDD machines use drill head that will be push through the ground. The drill head is
usually angled (figure 6-5), so that constant rotation of the drill string produces a
straight bore, whereas keeping the head in one position causes the line to change
in direction.
iv. Pilot drilling is done from point A (starting hole) to point B (receiving hole) as
shown in figure 6-4.
Figure 6-8 : The Position of Angle Bit during Inclining and Declining
xii. From the bore head flows a high pressure jet of drilling fluid. Boring is
accomplished through the cutting action of the jet of fluid and/or rotating a drill bit.
xiii. The contractor shall plot and record the actual of horizontal and vertical alignment
of the pilot bore for every interval of 6 meter (point of walkover) or maximum of 9
meter
6.5 Reaming
Reaming is a process of enlarging the bore hole after pilot hole process as shown in figure
6-9 below.
1 12 2
2 16 4
3 20 6
4 24 8
5 36 12
i. Once the reaming process is complete at point A, the HDPE duct shall be
pulled back into the reamed hole from point B to point A as shown in
Figure 6-11.
iii. Excavate a new trench with suitable depth to allow connection between existing
PVC and HDPE duct
iv. Wipe and clean both ends of the conduits
v. The outer surface of the HDPE duct shall be smoothed by using sand paper.
vi. The Inner surface of HDPE shall be trimmed by using grinder
vii. The end of the PVC duct shall be heated to expand the diameter of the conduit.
Additional excavation is needed during the initial pilot hole process, where starting and
receiving holes are excavated as explained in Figure 1. It is important that the correct
backfill materials are utilized. The compaction shall be done on layer-by-layer basis.
Backfilling of trench for open cut method in carriageway shall be done by using clean
sand.
i. Pour a layer of 50mm sand into the trench and compact the layer.
ii. Repeat the step (i) until the sand level reach the road base level.
iii. Lay the uPVC slabs/warning tapes along the route alignment at the depth range
of 450mm to 600mm from the ground level as shown in Figure 6-15. Take a
picture that shows the depth of uPVC slab/warning tape for evidence and
documentation such in Figure 6-16.
i. Backfill the trench by pouring a layer of 50mm earth and compact the layer
properly.
ii. Repeat step (i) until the trench is fully covered with the earth.
iii. Lay the uPVC slabs/warning tapes along the route alignment at the depth range
of 450mm to 600mm from the ground level as shown in figure 6-17.
a. In Carriage Way
i. Spread evenly and compact the 250mm thickness (or similar to the original
thickness before excavation or as instructed by local authority) of crusher run to
prepare of receiving the layer of asphalt premix.
ii. Pour the asphalt premix with the thickness of 50mm (or similar to the original
thickness before excavation or as instructed by local authority) onto the crusher
run layer.
iii. Compact the layer of the asphalt premix by using rammer machine such as
vibrator as shown in Figure 6-18.
iv. TM SPV shall ensure that there are no changes in the level of surface at the
excavated area after the road instatement work is complete. Contractor shall
bear any cost for additional work to repair the damage.
b. In Grass
The reinstatement of excavated area in grass is done by re-planting the grass and
plants which were removed during excavation.
Mandrel test shall be performed to clean and test the bore of the ducts. Upon the
completion of the duct line between any two jointing chamber or sites, the
cylindrical brush connected to the following end of a mandrel shall be passed twice
through each 'way' to clean the duct and to remove any foreign material which may
have entered. The test shall be carried out in the presence of TM SPV and any obstruction
or other defects found shall be rectified. TM SPV shall ensure that the draw rope have
been installed in one of the new cable duct-way.
8 MATERIAL
a. The material used as the duct-way for HDD work must be HDPE Duct Pipe PN10
Diameter 110mm with SIRIM approval. TM SPV shall check and ensure the material
used shall comply with TM’s specification.
b. The HDPE pipe shall be without any significant dimensional or surface deformities and
shall be free from visible crack, holes or defects.
c. The HDPE profiles as shown in Figure 8-1.
Figure 9-2 : The Use of Base Support or Platform during Excavation Work
iv. The boring liquid shall be dealt with carefully and shall not stain the road.
i. All workers shall be equipped and complied with the usage of personal protective
equipment such as safety helmet, safety boot, safety vest etc.
ii. All equipment shall be ensured in good condition
i. The handling of the joined HDPE shall be in such a manner that the duct is not
damaged by dragging it over sharp or jagged objects.
i. All drilling fluids shall not enter the streets, manholes, sanitary and storm sewers,
and other drainage systems, including streams and rivers.
ii. Any damage to any highway or non-highway facility caused by escaping drilling
fluid, or the directional drilling operation, shall be immediately restored by the HDD
contractor.
The minimum clearance from electricity supplies are shown in Table 9-1.
Minimum Remark
Cable
Clearance
Figure 9-3 : The Minimum Clearance between TM Duct-way and TNB cable
The minimum clearance between TM duct-way and TNB cable shall be 500mm which is
higher than as specified by MCMC (Doc No: SKMM/G/01/09).The minimum clearance is
decided based on higher safety measure after taking consideration on the nature of HDD
work.
The minimum clearance from other services shall be 152mm. In no case shall the
clearance be less than 50mm in all situations provided the approval has been obtained
from the authority concerned as in figure 9-4.
Figure 9-4 : Standard and Minimum Clearance of TM Infra from Other Services Plant
10 DOCUMENTATION
AND shall retain and keep these documents in the file project for the purpose of
acceptance test and handover process;
1. As-built drawing.
i. The depth of the duct-way (vertical alignment) for every 6 meter interval (See
Figure 6-1).
ii. The setback distance.
The retention period shall in line with the retention period of the project file. Please refer to
the ATP for the form and format of the documents
11 ACKNOWLEDGEMENT
The following persons have contributed valuable information during preparation of this
technical instruction:
4 Noor Fadlee Muhammad Hairi Manager Division Planning & Project Management
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