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Microtunnelling/Pipe
Jacking Construction
Pr9787
Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
Documents Details
This document is only valid on the day it was printed.
Version Review
Revision Reviewed by Approved by Date approved Revision type
0.1 B.Maule First Draft from Consultant
1.0 B.Maule B.Maule 21/06/216 Final Review of Draft
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
Contents
1 Purpose ....................................................................................................................... 6
2 Scope........................................................................................................................... 6
2.1 Definition .............................................................................................................. 6
2.1.1 Slurry Microtunnelling ............................................................................... 7
2.1.2 Earth Pressure Balance Microtunnelling ................................................... 7
2.1.3 Pilot Tube Microtunnelling......................................................................... 7
2.1.4 Vacuum Microtunnelling............................................................................ 7
2.2 Order of Precedence ............................................................................................ 7
3 Standards, Codes and Regulations ........................................................................... 7
3.1 General................................................................................................................. 7
3.2 Applicable Legislation and Regulation .................................................................. 9
3.3 Codes of Practice (ratified by Legislation)............................................................. 9
3.4 Codes of Practice (not ratified by Legislation) and Industry Guidelines ................. 9
3.5 Principal/Standard Drawings............................................................................... 10
4 Definitions, Abbreviations, Acronyms..................................................................... 10
4.1 Definitions........................................................................................................... 10
4.2 Abbreviations and Acronyms .............................................................................. 12
5 Project Preliminaries ................................................................................................ 13
5.1 Approvals ........................................................................................................... 13
5.2 Design ................................................................................................................ 13
5.2.1 Jacking Pipe ........................................................................................... 15
5.2.2 Carrier Pipe............................................................................................. 15
5.2.3 Design Collaboration............................................................................... 16
5.2.4 Safe Man Access.................................................................................... 16
5.3 Governing Documentation .................................................................................. 16
5.4 Risk and Contingency Plans ............................................................................... 17
5.5 Geotechnical Information and Risk ..................................................................... 18
6 Procurement.............................................................................................................. 19
6.1 Approved Suppliers ............................................................................................ 19
6.2 Principal Supplied Materials................................................................................ 19
6.3 Storage and Security of Materials ....................................................................... 19
6.4 Personnel ........................................................................................................... 19
6.5 Plant ................................................................................................................... 20
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
List of Tables
Table 1 – Design Drawing Requirement ........................................................................... 15
Table 2 – Work Plans ......................................................................................................... 16
Table 3 – Work Procedures ............................................................................................... 16
Table 4 – Safe Work Method Statements.......................................................................... 17
Table 5 – MTBM Personnel Experience ............................................................................ 19
Table 6 – Jacking pipe type and usage ............................................................................ 23
Table 7 – Jacking Pipe Standards..................................................................................... 23
Table 8 – Microtunnelling/Pipe Jacking Record/Report .................................................. 26
Table 9 – MTBM Guidance System ................................................................................... 28
Table 10 – Microtunnelling Survey Audit Requirements ................................................. 29
Table 11 – Allowable construction tolerance ................................................................... 30
Table 12 - Inspection and Test Plan.................................................................................. 35
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
1 Purpose
1.0.0.1 The purpose of this Specification is to ensure consistency across all projects
delivered by Unitywater and that the safety, quality, environmental and design
objectives required by Unitywater are achieved on Microtunnelling/Pipe Jacking
projects.
1.0.0.2 This Specification shall be read in conjunction with relevant project drawings (where
applicable), Job Specification and supplementary specifications.
2 Scope
2.1 Definition
2.1.0.1 Microtunnelling/Pipe Jacking shall, for the purpose of this document, be defined as a
trenchless construction method for installing pipelines which is:
Controlled:
o The microtunnel boring machine (MTBM) is typically operated from a
control panel at the surface;
o The system will generally install pipe simultaneously as spoil is excavated
and removed;
Guided:
o The guidance system shall reference fixed points in the MTBM and shall
be capable of installing the pipes to the required tolerance for line and
level;
Jacked:
o The process of constructing the pipeline shall be by consecutively pushing
pipes and the MTBM through the ground using a jacking system for thrust;
o Alternatively, the pipe can be pushed/jacked into the ground after the hole
is excavated provided that the drive is in competent ground able to self-
support until the pipe is installed;
Supported:
o Most microtunnelling/pipe jacking drives are able to provide continuous
pressure to the face of the excavation to balance ground, groundwater
and earth pressures;
o However, in some instances with competent dry ground full face support
is not required and the Contractor will employ a machine unable to
provide pressure to the face.
2.1.0.2 To avoid confusion within this Specification the term ‘microtunnelling’ will be used to
describe any works that include the use of a microtunnel boring machine and/or pipe
jacking system for the installation of a pipeline with minimal surface disruption. For
clarity the definitions of microtunnelling/pipe jacking provided in Section 4 shall be
referred to.
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
5 Project Preliminaries
5.1 Approvals
5.1.0.1 Project approvals are usually obtained by Unitywater; however, in some instances
approvals may be the responsibility of the Contractor. The Contractor is to refer to
the Project Specific Specification for required approvals.
5.1.0.2 No work is to begin, either onsite preparation or with Microtunnelling activities, until
all relevant permits and approvals have been gained and signed off by the relevant
authority. The following authorities may be required to authorise the works:
Queensland Government Department of Transport and Main Roads;
Queensland Rail and / or other rail infrastructure owners;
Local Government;
Private land owners.
5.1.0.3 The Contractor shall be required to adhere to any approval conditions that the
Principal or asset owner specifies.
5.2 Design
5.2.0.1 The Contractor shall be responsible for the design and construction of all aspects of
the microtunnelling works, including any temporary works and temporary pit/shaft
supporting structures.
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
Procedure Submission
Settlement Monitoring Plan 4 weeks before work
Major Lift Plan(s) 4 weeks before work
Plant Suitability and Maintenance Plan 4 weeks before work
Risk and Contingency Management Plan 4 weeks before work
Microtunnelling Inspection and Test Plan 4 weeks before work
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
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Document No: Pr9787
Revision No: 2
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Next Review Date: 20/06/2020
6 Procurement
6.1 Approved Suppliers
6.1.0.1 The Contractor must provide materials that have previously been approved for use
as per the SEQ WS & S D & C Code Infrastructure Products and Materials (IPAM).
6.1.0.2 If the Contractor proposes to utilise non pre-approved products these are to be
submitted to the Superintendent’s Representative for consideration.
6.4 Personnel
6.4.0.1 Appropriately trained and experienced personnel are required for the delivery of the
Works. Table 5 below summarises the minimum training and experience required for
key personnel. Details of key personnel experience shall be provided to the
Superintendent’s Representative for approval before the works commence.
6.4.0.2 A site supervisor who is thoroughly knowledgeable of the equipment and
microtunnelling procedure shall be present at the job site at all times. The site
supervisor shall be present to immediately address microtunnelling concerns, health
and safety and environmental issues.
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Document No: Pr9787
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Document No: Pr9787
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6.5.3 Jacks
6.5.3.1 Each set of jacks in the launch pit shall be fitted with suitably calibrated pressure
gauges in good working order and such that actual jacking forces can be read at any
time during the jacking operation.
6.5.3.2 The load from one ram or combination of rams shall be limited to avoid damage to
the lead pipe. The jacking load shall be transferred to the jacking pipe through a
jacking ring, which shall be sufficiently rigid to ensure even distribution of the load.
6.5.3.3 The jacks are to measure jack thrust pressures, stroke position and stroke speed.
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Document No: Pr9787
Revision No: 2
Last Review Date: 20/06/2018
Next Review Date: 20/06/2020
6.6 Materials
6.6.0.1 Permanent materials are to fully comply with this specification and the documents
referenced herein. The Contractor shall prepare and submit supplier’s certificates for
all permanent materials to be included in the works.
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Document No: Pr9787
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Permanent Uses
Type Casing/Carrier Pipe
(usually gravity)
GRP Storm Water/Trunk
Casing or Carrier Pipe
(Glass Reinforced Plastic) Main/Sewer
Steel Casing Pipe N/A
Concrete Casing or Carrier Pipe Storm Water/Trunk Main
Storm Water/Trunk
Polymer Casing or Carrier Pipe
Main/Sewer
Storm Water/Trunk
HDPE Lined Concrete Casing or Carrier Pipe
Main/Sewer
Storm Water/Trunk
Vitrified Clay Casing or Carrier Pipe
Main/Sewer
6.6.1.2 The Contractor is to source and use jacking pipe to the appropriate standard as
outlined in Table 7 below.
Table 7 – Jacking Pipe Standards
Type Standard
GRP (Glass Reinforced Plastic) DIN 16869 & DIN 19565
Steel To achieve temporary works loadings
Concrete AS / NZS 4058
Polymer Concrete DIN 54815-1 & DIN EN14636-1
HDPE Lined Concrete AS / NZS 4058
Vitrified Clay EN 295
6.6.1.3 For tunnels 900mm in diameter or greater, lubrication ports are required every 15 m.
The lubrication ports are to be spaced evenly around the jacking pipe circumference
at 120 degrees and be complete with a sealed one way valve.
6.6.1.4 The Contractor shall appropriately choose a jacking pipe jointing and packer system
to suit the pipe’s purpose and the tunnel alignment (allowable joint deflection). The
Contractor shall handle the jacking pipe as per the corresponding specifications and
manufacturers guidelines.
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Document No: Pr9787
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7 Project Execution
7.0.0.1 The Contractor shall maintain control of site operations at all times.
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Document No: Pr9787
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Document No: Pr9787
Revision No: 2
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Next Review Date: 20/06/2020
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Document No: Pr9787
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7.6 Microtunnelling
7.6.3 Microtunnelling
7.6.3.1 During microtunnelling the Contractor shall ensure that the following conditions are
met:
Jacking forces are within the allowable loads accepted by the jacking pipe
manufacturer and the design checks of this specification;
The jacking pipe joint deflections are within the allowable angles stipulated by the
jacking pipe manufacturer;
Tunnel and MTBM access is conducted as per the documentation, specifications
and standards;
The tunnel excavation does not exceed an acceptable ground loss percentage in
line with calculations;
The tunnel and MTBM follows the designed alignment within the tolerances
specified in Section 7.6.6 below;
The tunnel only commences when there is adequate jacking pipe available;
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Document No: Pr9787
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7.6.4 Lubrication
7.6.4.1 Should outer annulus lubrication of the pipe be shown to be required in the thrust
calculations, pipe lubrication shall be carried out by injecting a suitable, pressurised
lubricant through preformed holes in the jacking pipe or at the cutting edge of the
microtunnel boring machine.
7.6.4.2 Drilling fluids used shall be biodegradable.
7.6.4.3 Outer annulus lubrication is only employed when man access is possible. It is
preferred that the lubrication system employed is automatic and it operates to a set
volume or set pressure.
7.6.5.3 Details of the proposed guidance and steering system shall be forwarded to the
Superintendent’s Representative, for approval, prior to works commencing.
7.6.5.4 There are typically three MTBM guidance systems to choose from in the survey of a
microtunnelling operation. These guidance systems and the criteria that the
Contractor is to choose the appropriate system as described in Table 9 below.
Minimum
Drive Drive Survey Requires
Drawing Details Tunnel
Length Type Technique Man Access
Diameter
Laser Target
< 200m Straight Any Conventional No
System
Theodolite
Straight or
based Survey > 200m 900mm Conventional Yes
Curved
System
MTBM Gyro Straight or Non-
> 200m 900mm* Yes
System Curved Conventional
* Curved microtunnels of diameter <900mm may be possible using a gyro based system however
recommendations for alignment design and equipment selection should be sought from specialist
trenchless engineers.
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Document No: Pr9787
Revision No: 2
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Next Review Date: 20/06/2020
Microtunnelling Survey
Audit Requirements
Conditions
Survey Frequency &
Tunnel Length Man Access Audit Type
Technique Location
Surface and Pit
< 200m No Conventional Checks of 1 mid drive
Survey Control
Surface, Tunnel
and Pit Checks
< 200m Yes Conventional 1 mid drive
of Survey
Control
1 between 100-
Non-
200 – 400m Yes* Gyro Campaign 120m of drive
Conventional
start
1 between 120-
170m of drive
Non-
> 400m Yes* Gyro Campaign start and 100m
Conventional
from finish of
drive
* For tunnels with man access, but insufficient space for a successful gyro campaign to audit the TBM guidance (typical
diameters 900mm to 1500mm) then the Contractor shall document within the Survey and Guidance Management Plan a
method for maintaining and auditing the accuracy of the TBM based guidance system.
7.6.5.6 Construction control points shall be established sufficiently far away from the work so
as not to be affected by ground movement caused by the construction operations.
Such control points shall be checked regularly against permanent bench marks to
ensure the accuracy of the tunnelling is not compromised by ground movement.
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Document No: Pr9787
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7.6.9 Interventions
7.6.9.1 Man access to the tunnel and MTBM can be summarised into two cases: under
normal atmospheric conditions and under compressed air conditions.
In normal atmospheric conditions, the Contractor is to access the tunnel according to
the Confined Space Code of Practice (2011) Workplace Health and Safety
Queensland, Queensland Government.
When compressed air access is required the Contractor is to adhere to AS 4774
Work in Compressed Air and Hyperbaric Facilities.
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Document No: Pr9787
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Document No: Pr9787
Revision No: 2
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Next Review Date: 20/06/2020
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Document No: Pr9787
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8.3 Chlorination
8.3.0.1 When chlorination testing is required, the test shall be undertaken in accordance with
Unitywater’s Procedure for the Determination of Acceptance of New Mains (Pr9032)
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Document No: Pr9787
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Document No: Pr9787
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Next Review Date: 20/06/2020
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Document No: Pr9787
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Contractor Principal
Responsibilities Responsibilities
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Document No: Pr9787
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Contractor Principal
Responsibilities Responsibilities
Commissioning
CCTV Inspection - if required ☐ ☐ ☒ ☐ ☐ ☒
and Hand Over Red Line Drawing ☐ ☐ ☒ ☐ ☐ ☒
As Constructed Survey ☐ ☐ ☒ ☐ ☐ ☒
Submission of all Project ☐ ☐ ☒ ☐ ☐ ☒
Records/SEQ WS&S D&C
Handover Deliverables
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