1 ACCESSORIES EQUIPMENT 1 (CCPY) WATER THOHTMESS‘METHOD STATEMENT FOR PIPE. JACKING > STANDARD PROCEDURES FOR PIPE JACKING WORK: ‘Stemi: Construct jacking pt an receiving pit to comect level and size as per PE desien to suit both jacking operation as well as permanent manoles. ‘To make provision for: (2) Thrust wall atjacking pit (©) Pump sump for dewatering operation to suit eleiicl powered jacking machine (©) Clearance for lowering end ling of jacking shield (@)_ Clearance for the twansit or exit of shield and jocking pipes {@) Allowance for guardrail nstallation athe asking pit ‘Sin: Construct trust wall as required, The coneree thrust walls built for transiting 1nd dispersing the acking reaction force tothe natural ground behind the jacking shaft. ‘Sup: Install guide rail to coret alignment and level, Supe Install main jacks and laser survey system. The jacks are set up together with avcessries such as pressure plate, thrusting and guide ral ‘The jacking equipment, the laser, the pit bypass unit andthe discharge pump are ‘set up inside the jacking sha ‘Sup: Installation of supporting jacking systems including jacks, spoil disposal nd lubrication system. The sting taaks and water tanks are installed near the jacking shaft ‘onthe surface, The piping between these tanks and to the jacking shai place to form & sur circuit. The charge pump is setup near the water tank, Operation bourd ofthe jacking machine is setup, and then connect the power and ‘control cables to the operation board, the main power supply and other ancillary exinman Hyde hoes beoween Ge power prc andthe aking eqement ae sonnetStep 6 Lower jacking machin nt the jacking sha and place it onthe guide ris ‘The flexible hoses for sur pipes are connected tothe jacking machine from the pit bypass unit, and then the power and contol eables are connected to provide the power and te emote contol Sept Fil he slurry tanks with water an test run de sluny mack the slary pumps to ensure thatthe whole system is ready for operation. ‘Sep Hack Cut the shoring wal for jacking machine enty ‘Sup Activate jacking machine. ‘Step 10: Activate spoil disposal transportation system and lubrication system and ‘commence jacking ofthe shield until the jecking machine hes flly entered the ground. ‘Subsequently un ‘Step UIs Lower appropriate diameter pipes and connect it to the jacking machine and continue jacking. “Bentonite” for lubrication shall be pumped to the extemal side ofthe jacked pipes, using the lubrication systems, to reduce skin fetion as required Joking rate, spoil charging and discharging rate jacking fore, alignment end level are contisuoasly monitored and conelle at the remote central panel ‘Step 12: ‘When to jacking machine reaches the receiving shat, the shoring walla the exit font is then cut allow is ent. Step: Disconnect the jacking machine ftom the jacked pipes.ep 1 Dismantle of jacking accessories inside the completed pipaine and at the jacking sal Step 15: ‘Clean inside the completed pipeine. Sep 16 Demabilizaton to another jacking sha,METHOD STATEMENT FOR PIPE JACKING > DETAILS OF MAJOR PIPE JACKING OPERATIONS: PREPARATION WORKS AT JACKING SHAFT Pir to setting up the pipe jacking equipment inthe working sbaf he following reparation works willbe completed i. The shaft base tobe cast tothe coneet level to recive the jacking riz. The base sab shall incorporate sump pit for installing an electric pump. ii, Thoshaf shall be kept dey. 4k A suitable accessadder way is installed. ‘The access shall be such that it ‘will not interfere with the jacking equipment instalation. iv. Suitebebariction willbe provided around the shat tp by using GI Pipes Protective barr, ¥. Working site layout will be established with consideration being given to survey sight lines end such ike b. SETTING UP OF JACKING RIG (Min Jacking Station) The jacking rg comprises of jcking cylinders, a thnust plate and a guide rail assembly. The units are supplied separtcly and are assembled inthe shaft botiom. Sequence of he assembly is mentioned below: i. Checktovel fst base ii, Exablish ine of drive aro shaft bottom, ii, Set jacking ig guide rail assembly to line and level. Once in position scare with sel srt to shaft wall peasure no movernet can Oost in any diction iy. Fix thrust plate to the guide rail assembly and set to comeet vertical slignment Place in-situ conerste backfill between the thnist plate and shaft wall to form the thrust wall‘At this stage, the jacking machine is installed / assembled on the guide nil. The rest of the main jecking rig, including the jacking eylinder, is thea constructed behind the machine. INSTALLATION AND LAUNCHING OF THE SLURRY MACHINE, Sequence of the launching is a follows: - i. Plave the font section ofthe jacking machine in position of the jacking rig guide rail assembly ji, Push the machine forward with shor stoke of aul jacks up to the face of concrete soft eye ofthe chat wal i, To effect this operation, the hydraulic jacks are extended and retracted umber of times. Spacer blocks are placed between the hydraulic jacks tnd the machine alter each stoke to mave the jacking machine forward, iv. Setup the laser theodolite in font of the thrust pate of the jacking vig, The laser theodolite is fxed onto a stand constucted in font ofthe thst wall ¥% Connect up and test machine funtions and note survey parameters ready for lminch Vi. Check the pt bypass unit and the slury pumps to be operational and to ‘ensure there i ciralation of the slurry between the shury machine and the sy tank vii, Place push ring in suitable positon on base assembly to faci insallation of main jacking eylindrs. Place the jacking cylinders in postion between the thrust pate and the ust ing. ix Advance jacking machine slowly trough the entrance ring of sha wall Xx After the jacking machine ie driven into the ground, the opertion of the ‘machine nd slury pumps will be stopped. The electric cables and shury pipes are disconnected inthe jacking shaft, inorder to allow the conerete pies to be lowered oto the guide rails. xi, Install frst consrete jacking pipe together with all service lines. The service lines are supplied in mulples of pipe lengths. All services are disconnected prior to installing each new pipe in the line and reconnected Jmmediately afier each pipe has been insulled in the jecking rig.Switching mechenisms and valves are incorporated in the sbaft bottom ancillary equipment and included with the machine supply. vil, During driving, the operator contols the jacking speed, the torque ofthe cater head, slurry low rate and slurry pressure atthe work face andthe inclination of he slurry machine, viii, When the main jacks reach the end of stoke, they are rezacted. The spacer is put in plac to supplement the jacking stroke if necessary. INSTALLATION OF PIPES ‘The sewer pipes are usally delivered to site complete with softwood packers and proprietary rubber sal fixed ‘The instalation sequence i: i. Inspect eack pipe on the surface prior to lowering it inside the sha ‘Damaged pipes are identified with a red ross and are rejected. ‘Brackets for service lines are fied and service extension pipes! cables placed in the pipes to suit underground requirments. fi, Bentonite connection hoses snd valves are Gted to pipes cast with injection pos in them, iv. When the main jacks! push ring has been retracted from advancing the ‘previous pipe lower the next pipe into postion onthe guise al '¥. Extend the main jacks o push the conerete pipe forward unt itis fited to the tal ofthe jacking machine. vi. Once the concrete pipe is connected into the machine, the pipe jacking process continues until the whole pipe is ack into the ground as describe below. vi, Lubricate the ruber seal with approved lubricants ‘ili Advance new pipe to make joint with previous pipe checking tha rubber seal engages correctly i Rum the slury pumps, operate the pit bypass unit rotate the cutter head, and ented the main jocks to resume the pipe Jacking operation.‘Repeat extending and retracting operations of the jacks until the concrete pipe i lowered inte the shaft and placed on the guide rails Reconnect the elect cables andthe slurry pipes to the jocking machine. Run the slany pumps, operate the pit bypass unit, rotate the cuter head ‘and extend the main jacks to resume the pipe jacking cpertin. Repeat extending the retracting operations of the main jacks to push the pip into the ground, ‘While the pipe jacking operation is earied out, the lubricant is pumped continuously othe periphery ofthe concrete pipe to reduce ction, Repeat jacking operation till the shiny machine comes close 10 the receiving pit ‘Comneeal service lines, ‘When the slany machine is about 300mm befor the receiving shaf, the jacking operation is halted. A small hole is dill trough the shat wall, ‘0 confinm the position of the jacking machine and to make sure tht there ‘is no groundoraer igre, ‘The guide mil are sett rosive the jacking machine Break the wall ofthe receiving shat and resume the jacking operation to sh the jacking machine into the receiving shaft ‘After the jacking machine is completely driven into the receiving haf, it is removed and lifted tothe surface, Remove all fils, Service lines to the jacking machine and tunnel comprise of: Electric power cable to cutting wheel Control eabl fiom jacking rg Bentonite lubrication line, sy connection hoses Lighting Ventilation ducing EXCAVATION VOLUME CONTROL (Using Flow Meters) (Over excavation in sot ground produces surface settlement and under «excavation produces surface heave, bth conditions are undesirable and must be avoidedTo assist the operator, acts] volume of sy excavated is monitored by recording the flow rates on the flow meters ofthe charge and ditcharge pump= andthe excavation speed. From this information the actal excavated volume ‘ean be calculated and compared against the theoretical volume of earth excavated. ‘The operator wll then be able to monitor the volume of excavation to prevent ‘over and under excavation, LUBRICATION SYSTEM ‘The lubrication system using "Bentonite" to reduce the friction berween the consree pipe and ground. Lubrication wil be eavied out manually daring the Jacking operation it i done by injecting the lubricant at regular intervals. The ‘Bentonite volume would be caleuated based on the annul of void die to over cating ofthe shield cuter hea. BREAKING THROUGH AND REMOVING THE MACHINE FROM, RECEIVING SHAFT: Prior to the jacking machine reaching the receiving shat, the following reparation works and access facilities will be made avilable: “+ Shaft consti including base eb, ‘+ Access inside the temporary shaft and suitable igting, ‘+ Protective barrier at ground level. [Breakthrough sequeace sas follows: - ‘© Advance the jacking machine with cation on approaching concrete wall of shat. ‘© When jacking machine hits the caisson wall, ack and roduce the ‘thiskness of wal by 50% from the receiving shaft and expose the BRC. (oresisson, ‘+ Cuta small opening to se the jacking machine esd, Affe locating the jacking machine, cut the BRC, if ight adjustments hhave to be made, hack the concrete wall eccordingly. 1+ Advance jacking machine epee bed of ering whe in rceving ‘+ Advance the jacking machine through the opening until rot section is {ally exposed, ‘+ Advance remaining portion of the machine and remove it fom the shat‘+ Advance leading pipe to required position in reception sha h, NAVIGATION SYSTEM FOR PIPE JACKING: Pipe jacking is done withthe help of Laser Theodolite system. The laser theodoite is set infront of the trast walla the jacking sha, Daily checks will ‘be caried out to ensure that the laser theodolits is sex comecty peor 10 jacking ‘works. During jacking operation, the operator will be guided by the laser athe ‘target in the jacking machine. The operator will contol and adjust the seeing of ‘the jacking machine to maintain the correct alignment and level Note ‘After completion ofjecking lin the frst and last tobe conneted tothe shot pipe by casting ‘+ Inozder o syed flooding in shaft durng ning season, here isa aiomatie elect pump will 'bopace nthe dela pit of tha af. Alb a werk wil tay at nighties order to counter ‘huckand make sure that here isn lading inthe sh Also Earth bund wl be conte around the shaft at level higher than the grord evel + Confined space assessing (es menitring test) wil be conducted before worker enter into the ie to werk. Every four hur te gas monitoring willbe conducted to ensue there is 20 ‘combustible, amnable gs er iesde he pipe.