Abu Dhabi Sewerage Services Company (ADSSC) Contract No.

: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

SECTION P2003

MICROTUNNELING AND PIPE JACKING

Rev.0
 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

SECTION P2003
MICROTUNNELING AND PIPE JACKING

1 GENERAL

1.1 INTERPRETATION
The following Specifications are the Microtunneling and Pipejacking requirements which
amend or supplement the Non-Destructive Method requirements contained in Section
02400 of ADSSC Specification. In case of any discrepancy between these
Microtunneling and Pipejacking requirements and the Non-Destructive Method
requirements (Section 02400 of ADSSC Specification), the provisions of these
Particular Specifications take precedence over the ADSSC standard requirements.

1.2 SCOPE AND GENERAL REQUIREMENTS

a. The work of this section includes, but is not limited to, providing all labour,
materials, tools, equipment and incidentals necessary for pipe jacking and
Microtunneling operations in accordance with the Contract Documents.

b. This is a performance specification. The Contractor shall be responsible for the

design of the Temporary Works, Permanent Works and for the selection of the
tunnel boring machine and the tunnel construct ion systems.

1.3 REFERENCED DOCUMENTS

a. The following sections of the Specifications are referenced in this section:

i. Section 01000, General Requirements

ii. Section 02220, RC Pipelines. Materials Installation and Testing
iii. Section 03600, Concrete Protection and Waterproofing System
iv. Section P1001, Particular Requirements.
v. Section P1003, Health and Safety Requirements
vi. Section P2002, Temporary Work Shafts

vii. Section P2005, Protection of Existing Structures and Services

viii. Section P2006, Ground Treatment or Ground Improvement

b. The following standards, codes and guidelines supplement those stated under
Clause 1.3 of Section 02400 'Pipeline Construction By Non-Disruptive Method'. The
following standards shall be referred to as applicable:

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

i. BS EN 12620:2002 'Aggregates for Concrete'

ii. BS EN 12889:2000 'Trenchless construction and testing of drains and
sewers'

iii. BS EN 206-1:2000 'Concrete. Specification, performance, production and

conformity'
iv. BS EN 14364:2006 'Plastic p1p1ng systems for drainage and sewerage
with or without pressure. Glass reinforced thermosetting plastics (GRP)
based on unsaturated polyester resin (UP). Specifications for pipes, fittings
and joints '

v. BS EN 1636-5 'Plastics piping systems for non-pressure drainage and

sewerage. Glass-reinforced thermosetting plastics (GRP) based on
unsaturated polyester resin (UP). Fitness for purpose of the joints'

vi. ASTM A 139 'Standard Specification for Electric-Fusion (Arc)-

Welded Steel Pipe (NPS 4 and Over)'
vii. ASTM D4161-01 'Standard Specification for "Fiberglass" (Glass- Fiber-
Reinforced Thermosetting-Resin) Pipe Joints Using Flexible Elastomeric
Seals'
viii. ASTM D638 'Standard test methods for tensile properties of plastics'

ix. ASTM D 6783 'Standard Specification for Polymer Concrete Pipe'

x. ASTM C 579 'Standard test method for compressive strength of chemical
resistant mortars, grouts, monolithic surfacing and polymer concretes'
xi. DIN 54815-1 'Pipes made of filled polyester resin moulding materials -
Dimensions, material and marking'
xii. DIN 54815-2 'Pipes made of filled polyester resin moulding materials-
Requirements and testing'

c. British Tunnel Society: 'Model specifications for Tunneling' 2001. "Specification for
Tunnelling 3rd Edition": The British Tunnelling Society and The Institution of Civil
Engineers: Thomas Telford Ltd 2010.

d. CIRIA C577: 'Guide to the construction of reinforced concrete in the Arabian

Peninsula'.

1.4 DEFINITIONS

a. The use of the term 'tunneling' herein refers to excavation and installation of pipe
by either pipejacking or microtunneling methods, or other similar trenchless
method. The term 'tunnel' shall be taken to mean the installed pipeline, whether
during or after the completion of the installation.

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

b. Pipejacking is a trenchless technology of installing underground pipelines (between

900mm and 3500mm in diameter) by means of jacking specially designed pipes
through the ground from a jacking pit or shaft. The excavation is achieved by using
a cutting head at the forward end of the pipeline. Unless otherwise approved by the
Engineer, all shields shall be capable of providing continuous support to the face by
slurry or earth pressure balance methods.

c. Microtunneling is a trenchless technology for construction of pipelines (between

200mm and <900mm in diameter) . It is a remotely-controlled, guided, pipejacking
process that provides continuous support to the face (via a full-face micro-TBM)
without requiring personnel entry into the tunnel.

d. Tunnel Boring Machine (TBM) refers to the mechanised cutting unit, shield and
ancillary equipment, whether it be for microtunneling or pipejacking applications.

1.5 SUBMITTALS

a. Submittals shall be made in accordance with Sections P1001 and P1003.

b. The following submittals supplement those stated under Clause 1.4 of Section
02400 'Pipeline Construction By Non-Disruptive Method':

i. The Contractor shall submit a schedule for the submission of working

drawings and specifications for review. This schedule shall be agreed with
the Engineer.
ii. The Contractor shall submit a detailed schedule of manufacture/supply of
TBMs, back-up plant and equipment including delivery dates and testing
dates. The Contractor shall update progress on a weekly basis and
comment on future necessary action to maintain delivery date.
iii. Within 8 weeks after the Commencement Date, the Contractor shall provide
all details of the TBMs and back-up equipment, including all items specified
herein.
iv. The Contractor shall demonstrate that the TBM manufacturer has
manufactured at least three TBMs of similar type, size, and complexity,
used in successfully completed similar size projects with ADSSC .
v. The Contractor shall submit to the Engineer information on all proposed
drilling fluids, additives, lubricants and conditioning agents. Submittals
must include material safety data sheets on each material along with a
description of where the material will be used and its purpose in the
construction process. All drilling fluids and lubricants shall be bio-
degradable. Drilling fluids after usage shall be handled and disposed fully
complying with EAD permit/ NOC procedure and approval.

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Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

vi. Prior to the commencement of the Works the Contractor shall submit
calculations showing the estimated maximum jacking force for each drive.
The calculations shall take into consideration the frictional characteristics of
the ground and the pipe material, the type of lubricant, the depth and the
diameter of the pipe and the required length of the drive.
vii. Prior to commencement of works, the Contractor shall design the pipes for
adequate strength for NDM works considering ground characteristics and
jacking force, etc. Contractor shall submit the design calculations for
Engineer's approval.

viii. The Contractor shall submit the details, method statements and
specifications for the final pipe systems selected for construction, for
approval of the Engineer. These shall include: pipe materials; collar and
joint systems; corrosion protection lining; grouting; intermediate jacking
stations and locations in drives; break in/out from shafts, soft eyes and
seals.

ix. The Contractor shall prepare a Gas Characterization Programme, detailing

the methods and frequencies for monitoring of hazardous gases.

c. Clause 1.4.2 i.) of Section 02400 requirements are amended to a Geotechnical

Design Report, which:

i. May be separated into the different elements (based on geographic location

and type of pipe jacking or microtunneling;
ii. Includes any additional geotechnical investigations and testing (factual
data) undertaken by the Contractor post award;
iii. Summarises the anticipated ground conditions for each work shaft and
pipeline drive;
iv. Presents the basis for the selection of particular TBMs and cutter face
arrangements;
v. Presents the basis of design for all work shafts;
vi. Presents the requirements and basis of design for all dewatering and
ground improvement;

vii. Includes estimates of ground surface movements associated with the

excavations and pipeline construction ;
viii. Presents geotechnical risks and mitigating measures applicable to the
works.

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

2 EQUIPMENT

2.1 TUNNEL BORING MACHINES (TBMS)

a. The Contractor shall provide, install, maintain and remove on completion TBMs
suitable for excavation in the ground conditions as described in the specification
and the Contract documents.

b. The proposed TBM manufacturers shall be recognized commercial TBM

manufacturers with no less than 5 years of successful experience in the design and
manufacture of the type of TBMs proposed by the Contractor.

c. All TBMs for internal pipeline diameters greater than 1200mm shall be new or
newly refurbished/rebuilt, with all major components tested and guaranteed by the
TBM manufacturer. TBMs for pipelines between 600mm and 1200mm diameter
shall have a maximum of three thousand working hours, and shall have newly
retooled and refurbished cutterheads, and be supported by documentary evidence
of service history. TBMs/moles/drilling equipment for pipelines less than 600mm
diameter shall have a maximum of five thousand working hours, and shall have
newly retooled and refurbished cutterheads, and be supported by documentary
evidence of service history.

d. All TBMs provided must be capable of satisfactory performance in the anticipated

ground conditions as per the Geotechnical Interpretative Report and Geotechnical
Factual Report. Geotechnical investigation shall be carried out by The Contractor

e. The design of the TBM shield shall include an articulated joint as required to ensure
construction of the pipe jack/ microtunnel to the theoretical alignment as shown on
the Contract drawings.

f. The Contractor shall provide a TBM Guidance and Control System with laser
theodolite. This shall be a commercially manufactured system .

g. The TBM shall have a proven system for monitoring the presence of hazardous or
explosive gases. Systems shall be arranged with adjustable limits and shall have a
first level warning signal and a second level with automatic shut-off of equipment.
Gases to be monitored shall be methane, hydrogen, oxygen, carbon dioxide and
carbon monoxide.

h. The TBM shall be designed to withstand all the jacking loads as well as the full
overburden pressure and hydrostatic pressure.

i. The TBM shall be capable of fully supporting the face during both excavation and
shutdown periods, and shall have the capability of exerting a continuous,
controllable stabilizing pressure at the face as required to prevent loss of ground

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

and groundwater inflows.

j. Only TBM synthetic oils HFDU (biodegradable, fire resistant polyesters) shall be
used. All oils must be approved by the TBM manufacturer

k. In addition to above, TBM should also comply with the following requirements:

(i) Steerable and incorporating hydraulic rams to move the articulated head.

(ii) Designed to ensure no rotation or rolling during installation.

(iii) Remote controlled and can transmit information such as jacking force, face
pressure, length, roll, pitch, steering attitude, temperature, valves open or
closed, cutter torque, rate of progress, slurry pressure, slurry flow, earth face
pressure to a microprocessor console on the surface from where the system is
operated.

(iv) Incorporates meters and gauges to measure the slurry flow and
pressures.

(v) Capable of operating under groundwater conditions as necessary with a

hydrostatic balance not less than 3m head of water.

(vi) Fitted with a calibrated laser target, robustly constructed and rigidly secured.

(vii) Guidance system shall be laser or an approved equivalent for the control of
tunnel alignment. The guidance system shall be mounted independently of the
thrust wall or machine jacking rig or anything else that may move during
operations.

2.2 OTHER MICROTUNNELING EQUIPMENT

a. For small diameter (less than 400mm ID) microtunneling, the Contractor may utilize
non-TBM type equipment, to be approved by the Engineer.

b. The proposed manufacturer shall be a recognised commercial manufacturer with

no less than 5 years of successful experience in the design and manufacture of the
type of microtunneling unit proposed by the Contractor .

c. Any such techniques must provide continuous support to the boring face and
ground during pipeline installation, and prevent uncontrolled inflows of groundwater
and soil into the pipeline or muck removal system.

d. All microtunneling equipment provided must be capable of satisfactory performance

in the anticipated ground conditions as per the Geotechnical Interpretative Report
and Geotechnical Factual Report. Geotechnical investigation shall be carried out

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

by The Contractor

e. Non-TBM equipment for pipelines less than 400mm diameter shall have a
maximum of five thousand working hours, and shall have newly retooled and
refurbished cutterheads/boring tools, and be supported by documentary evidence
of service history.

2.3 PIPE MATERIALS

2.4 GENERAL

a. This Clause replaces Clause 2.2 of Section 02400 of ADSSC Specification

'Pipeline Construction By Non-Disruptive Method'.

b. Selected pipe material for micro tunneling and pipe jacking application for this
project shall be Reinforced Concrete Encased GRP Jacking Pipe.

c. Contractor shall design the GRP pipe stiffness for reinforced concrete encased
GRP Jacking pipe as per the requirement given below or on the recommendation
of manufacturer depending on pipe diameter and site conditions {soils, installation,
compaction, loads etc.) in compliance to the performance requirements and
warranty conditions specified in this document:

i. Minimum acceptable pipe stiffness for GRP pipe shall be 10,000N/m2 (SN
10000}, and subject to Engineer approval.
ii. A pipe system design demonstrating that wherever possible the reinforced
concrete encasement is not required for the satisfactory performance of the
pipeline with respect to dead and live loads; and Infiltration. If the resultant
pipe stiffness exceeds 20,000N/m2 (SN 20000}, then the encasement shall
be form part of the pipe system design. This is subject to Engineer Approval
iii. All reinforced concrete encased GRP Jacking pipe Installed beyond 20.0m
cover depth shall be designed as a composite pipe with GRP pipe stiffness
of minimum 20,000N/m2 (SN 20000}, and subject to Engineer approval.

d. The manufacturer of the pipe materials and pipes must demonstrate a 1a- year
recent history of successful installations in similar corrosive environments.

e. Warranty

i. The manufacturer and the Contractor shall jointly guarantee the completed
pipe system, Including any protective coatings and linings, to be free from
defects in materials and workmanship for a period of 60 years from the date
of completion of the Works.
ii. The Contractor shall furnish the Employer with the manufacturer's

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

guarantee and warranty certificates for all materials and components used.
iii. If the protective coating and lining system are found to be defective during
the warranty period, the manufacturer and Contractor shall replace and/or
repair the protective coating and lining system to the satisfaction of the
Engineer at no cost to the Employer and restart the guarantee.
iv. All pipe jointing systems and seals shall withstand a minimum external
water pressure of 4.5 bar.
v. The pipe and any fittings must be manufactured within six months of the
Contract commencement date.

vi. Before delivery, the manufacturer shall ensure that factory acceptance test
(FAT) has been undertaken and a factory acceptance certificate (FAC) shall
be submitted.

vii. Before delivery, the manufacturer shall submit a written "Certificate of

Compliance" that the pipe to be supplied meets all applicable BS, European
and ASTM Standards as referred to in the Specification.

2.5 CONCRETE ENCASED GRP JACKING PIPE

a. This section supersedes ADSSC Specification 02400 'Pipeline Construction By

Non-Disruptive Method' clauses relating to concrete encased GRP jacking
pipe.

b. Concrete Encased GRP Jacking Pipe design and performance requirement

includes:

1. Demonstration of the design and installation procedure ensures that the

reinforced concrete encasement takes the maximum jacking load. the
design shall ensure that the grp pipe is not subjected to any forces arising
from the jacking installation.
2. Provision of UAE and middle east case histories regarding the particular
pipe and joint system, ground conditions, drive lengths, water tightness
tests, and as-built tolerances and conditions.
3. Ensure that the manufacturer provides angular tolerances on installation
specific to this pipe system, supported by calculations justifying the
proposed tolerances .
4. A pipe system design demonstrating that the grp coupling is adequate to
achieve the structural, durability and water tightness requirements up to the
end of the design life, when installed at the limit of the angular tolerance
between pipes.

5. A pipe system design demonstrating that the encasement in concrete

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

results in no adverse chemical or physical effects to the grp pipe.

c. Unless superseded by clauses herein, the requirements of Section 02200 of

ADSSC Specification 'GRP Pipelines. Materials, Installation and Testing' apply.

d. Resin Systems: The manufacturer shall use only resin systems with a proven
history of performance in this particular application. The historical data shall have
been acquired from a composite material of similar construction and composition as
the proposed product.

e. Additives: Resin additives, such as curing agents, pigments, dyes, fillers, thixotropic
agents, etc., when used, shall not detrimentally effect the performance of the
product.

f. The inner liner of the pipes exposed to sewer flow shall be manufactured using a
vinyl ester resin with a 50% elongation (minimum) when tested in accordance with
ASTM 0638/ ASTM C581. The interior surface shall provide crack resistance and
abrasion resistance. The exterior surface of the pipes shall be comprised of a layer
which provides UV protection to the exterior.

g. Joints: Unless otherwise specified, the pipe shall be field connected with fibre glass
sleeve couplings that utilize elastomeric sealing gaskets as the sole means to
maintain joint water tightness. The joints must meet the performance requirements
of ASTM 04161.

h. Concrete encased GRP Jacking pipe shall be protected externally with an epoxy
coating to the requirement of Section 03600 of the ADSSC Specification .

2.6 OTHER REQUIREMENTS

a. Collars

i. Collars for butt-jointed pipes shall be designed for the specified design life,
and shall be manufactured from the following:
1. Steel alloys having a minimum Pitting Resistance
Equivalent Number (PREN) >40.
2. GRP: Joints utilizing GRP sleeve couplings must meet the
performance requirements of ASTM 04161 or BS EN 1636-5:2001.
3. Other material having equal or better performance than Steel Alloy or
GRP, subject to approval of the Engineer.
ii. Collars shall be cast integrally with and securely anchored to the pipes but
shall not be attached to reinforcement or associated spacers.

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Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

b. Bentonite and grout holes

i. Where pipe diameters are 900mm or greater, each pipe shall incorporate
a minimum of two sets of three bentonite injection holes spaced equally
around the circumference, on centers located at the quarter points from
either end of the pipe. Two of the grout holes in each set shall be located at
the soffit of the pipe.

ii. Pipes may incorporate lifting holes and fixing holes for securing temporary
apparatus, all holes shall be threaded to enable plugs, approved by the
Engineer, to be screwed into the sockets to withstand the external water
pressure. On completion of the tunnel and following grouting of the voids
around the pipe all holes shall be filled with a non-shrink cement mortar to a
mix approved by the Engineer.

c. Packing

i. This is supplementary to Clause 2.3 of Section 02400 'Pipeline Construction

By Non-Disruptive Method'.

ii. Packers shall be made of Medium Density Fiberboard (MDF) or any

material of similar mechanical properties, subject to Engineer's approval.
For MDF packers a thickness between 15 and 19mm and bending strength
of at least 20 N/mm2 are required.

d. Pipe Joint Sealing System

i. Pipe joints shall be designed to be watertight against both the external

water pressure head and any internal surcharge pressure, depending on the
depth and intended use of the pipeline. The integrity of the joint water-
tightness shall be guaranteed in writing by the manufacturer for the approval
of the Engineer.
ii. Sealing rings shall be manufactured using an EPDM ring(s) complying with
BS EN 681-1:1996 and guaranteed to perform satisfactorily for the whole
design life.
iii. All sealing rings shall have physical and chemical properties, including
hardness (measured in International Rubber Hardness Degrees - IRHD),
compatible with the pipe material. Sealing rings shall be stored in a clean,
cool condition out of direct sunlight and without being deformed. Sealing
rings for use with thermoplastic pipes shall contain no component which can
react with the material of the pipes.

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 Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

e. Lubrication and Conditioning Agents

i. This section is supplementary to Clause 2.4 of Section 02400 'Pipeline

Construction By Non-Disruptive Method'.

ii. The material used for lubrication shall be stored and mixed in a manner
recommended by the Supplier.
iii. It is the responsibility of the Contractor to assess and allow for the chemical
effects, if any, of gypsum or high salinity ground and groundwater, and/or
any contaminated ground encountered, on his proposed slurry and
lubrication fluids and any additives.

iv. Inert fillers such as limestone or sand may be added but no other materials.
Where inert fillers are proposed the sub-Contractor shall submit the material
type to the Engineer, for approval.

v. The term soil conditioning refers to the use of suitable additives

(conditioning agents) in various proportions to alter the soil properties of
the excavated spoil such as foams, polymers, slurries . The Contractor
shall seek compliance with both safety-in- use and disposal regulations. All
conditioners shall be inert and bio-degradable .

f. Contact Grouting

i. The following amends Clause 2.6 of Section 02400 'Pipeline Construction

By Non-Disruptive Method'.
ii. Grout shall be cementitious, containing between 2% and 4% bentonite with
a 7-day unconfined compressive strength of at least 3MPa per BS EN 206-1
:2000 and shrinkage less than 5%. Add sand to the mix for voids larger than
50mm.

3 EXECUTION

a. Shafts, Jacking and Receiving Pits

i. Refer to Particular Specification P2002 Temporary Work Shafts'.

b. Pipe Installation

i. This section is supplementary to Clause 3.5 of Section 02400 'Pipeline

Construction By Non-Disruptive Method'.
1. All pipes shall be installed in accordance with the manufacturer's installation
instructions.
2. If the Contractor's design requires that pipe jacking operations be driven in

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Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

a downhill direction then the Contractor shall submit to the Engineer his
proposals for ensuring the security of his operations against flooding of the
tunnel.

3. TBM operation shall be capable of maintaining ground control at the face to

complete the work without exceeding the ground movement limits specified
in P2005 'Protection of Existing Structures and Services'.

4. Earth Pressure Balance Machines shall be operated in closed mode.

5. Each pipe must be inspected for damage before installation and approved
for use by the Engineer. Pipe ends must be undamaged without any signs
of dirt or chipping. Defective packings and sealing rings must be
discarded before installation and joint sleeves must not show any dents,
damage or distortion .

6. Similar quality control shall be used for the slurry delivery pipe systems.
7. The angular deviations between pipe faces can cause severe localization of
stress and should be avoided. The angular deviation at each face shall not
exceed 0.15 degrees with a maximum total of 0.30 degrees.
8. Pipes should be straight and uniformly dimensioned, have squared ends
and have joints that are designed to allow for efficient load transfer from
pipe to pipe.
9. The jacking frame, jacks and steering head should be aligned along the
planned line and grade and shall be square and true to the thrust wall to
minimize eccentric loading. Steering corrections should be made gradually
to minimize abrupt misalignment angles between two pipes resulting in
eccentric loads.
10. Overcut around the circumference of the tunnel shield should be designed
to allow steering corrections to be made and lubricant to be injected to
completely coat the pipe exterior but the overcut should not be greater than
20mm on the radius of the skin of the shield.
11. The jacking frame and the capacity of the jacks shall be designed by the
contractor to ensure uninterrupted operation of the works. Calculations shall
be submitted to the Engineer for his information.
12. The TBM and associated equipment must be capable of monitoring slurry
pressures. Regular inspection of the ground surface and existing storm
water and sewer pipelines near underground slurry injection locations is
required to ensure that hydro fracture and loss of slurry is prevented and
managed.
13. Intermediate Jacking Stations: If the jacking force, after applying a safety
factor of 1.5, exceeds 75% of the maximum working load for the pipe, the

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Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

use of intermediate jacking stations is required. The Contractor shall notify

the Engineer in writing of his intent to install an intermediate jacking station.
14. The Contractor shall take a sample from either the separation plant (slurry)
or muck skip (EPB) once per day for each drive. Each sample shall be
minimum 1 litre in volume. The sample shall be bagged, sealed and
labelled with: Contract #, Drive/Line #, Date, Chainage. Samples shall be
stored in a secure building out of direct sunlight, and available for
inspection by the Engineer from the day following the sampling.

c. Constructions shift records shall be submitted to the Engineer and shall include:

i. Extent and causes of any delays.

ii. Face logs of the as-dug strata.
iii. Machine performance (advance rates, slurry flow rates, jacking thrust loads,
machine torque measurements).
iv. Computer output: grade and roll of MTBM, Torque and RPM of the
cutterhead , instantaneous jacking rate and total distance jacking rate,
indication of steering direction, volume of the slurry in both the supply and
the return side of the slurry loop, and indication of the pressure of the slurry
in the slurry chamber . All parameters should be logged in real time and
over distances.
v. Line and level of the lead pipe on completion of the installation of each pipe
during the shift.
vi. Records of mucking out and muck deliveries to disposal site, ticketed and
stamped at the disposal site.
vii. Copies of the shift records shall be submitted daily to the Engineer.

d. TBM Real Time Monitoring

i. Continuous data monitoring and logging of TBM performance shall be

submitted to the Engineer in real (instantaneous) time for the duration of
TBM excavation. Data collection shall be accomplished by automatic
electronic continuous recording systems. Data to be collected shall include
the following:

1. For every jacking shove or stroke, the date , time and station at start of
shove; duration of shove; type of soil; cutter head revs; drive speed;
average drive motor current or hydraulic pressure; power consumption;
thrust/propel cylinder pressure; number of operating motors; mode of
operation and cutter head chamber pressure; jacking pressure; inter jack
pressures ; lubrication and grout volumes and pressures.

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2. Slurry line pressure, flow, density, viscosity .

3. Gas monitoring and alarm.
4. Excavated volume against theoretical volume for the actual advance. The
system shall incorporate an audio visual l alarm with preset alert limits in
the TBM operator cabin to warn of potential over-excavation .
5. TBM orientation and deflection from line, level and grade, roll, and other
information provided by automatic data acquisition systems.
ii. The data acquisition system supplied to the Engineer's office shall allow the
Engineer to study and print out real time and historical data for each TBM
and guidance system via a dedicated computer and backup computer.
There shall be one dedicated data acquisition system per TBM to be
installed in the Engineer's office.

iii. Should the TBM guidance system not be part of the TBM data acquisition
program, an additional dedicated guidance system computer is required to
duplicate the data acquisition system's scope. Alternatives which require the
closure of the data acquisition program to view the guidance system are
not acceptable although separate windows running the data/guidance
programs simultaneously maybe acceptable, subject to the Engineers
approval.
iv. The data and guidance systems in each office are to be linked to the
network printers at the corresponding Engineers office.

e. Guidance and control system

i. This section is supplementary to Clause 3.7 of Section 02400 'Pipeline

Construction by Non-Disruptive Method'.
ii. The alignment shall be determined by a surface survey. Care should be
taken in the transfer of the survey to the shaft bases. The guidance is
achieved by using a self-levelling Laser transit unit.

iii. The Laser shall be mounted independently of the thrust wall so that minor
deflections of the wall would not result in inaccurate readings.

f. Grouting (external to pipe)

i. Immediately following the jacking operation the Contractor shall pressure

grout the jacked section to fill all voids existing outside of the pipe. Grouting
shall be from the interior of the pipe through grouting holes as specified.

ii. System of standard pipe, fittings, hose, and special grouting outlets
embedded in the pipe walls shall be provided by the Contractor. Care shall
be taken to ensure that all parts of the system are maintained free from dirt.

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Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

Grout composed of cement, sand, other Engineer approved compound and

water shall be forced under pressure into the grouting connections at the
invert and shall proceed until grout begins to flow from upper connections.
Connections shall then be made to those holes and the operation continued
to completion.
iii. Apparatus for mixing and placing grout shall be of a type approved by the
Engineer and shall be capable of mixing effectively and stirring the grout
and then forcing it into the grout connections in a continuous uninterrupted
flow.

iv. After grouting is completed, pressure e shall be maintained by means of

stop cocks, or other suitable devices until the grout has set sufficiently. After
the grout is set, grout holes shall be completely filled with dense concrete
and finished neatly without evidence of voids or projections.
v. For pipes with CPL's, grouting shall be carried out and the Contractor
shall ensure that the pipeline is watertight before proceeding with the
jointing of the linings of the pipes and the patching of the lining over the
filled grout holes. Grout holes patching shall be carried out using same
lining material.

g. Tolerances

i. This section is supplementary to 3.8 of Section 02400 'Pipeline Construction

By Non-Disruptive Method'.
ii. There shall be no pipeline backfall at any point.
iii. Any pipe which is not laid in its correct position must be adjusted to obtain
its correct position

h. Thrust Wall

i. This section is supplementary to Clause 3.4 of Section 02400 'Pipeline

Construction By Non-Disruptive Method'.

ii. The design of the thrust wall and any associated temporary works shall be
such as to prevent damage to any part of the Permanent Works.

i. Slurry Separation Plant

i. The excavated material from the face cut, crushed and mixed with the slurry
shall be separated and the water recycled or disposed of at a location
agreed by the Engineer. Cleaning of the slurry shall be achieved by using
either:
1. settling tanks, where the tank is cleaned by an excavator or grab, the

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Abu Dhabi Sewerage Services Company (ADSSC) Contract No.: O-14760
Supply Department Construction Works for Main Sewer Line
to Connect STP 1 to the Treatment Plant 2
on Saadiyat Island and remove STP 1

water is recycled and the solid material is disposed off site; or

2. Separation plant, where a separate unit of screens and cyclones
continuously removes the solids and recirculates the slurry for further
use or disposal.

END OF SECTION

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