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METHOD STATEMENT FOR PIPE JACKING

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CONTENTS

1.0 INTRODUCTION

2.0 MATERIAL

3.0 PLANT AND MACHINERY

4.0 MANPOWER

5.0 CONSTRUCTION

6.0 ENVIRONMENTAL, SAFETY AND HEALTH REQUIREMENT

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1.0 Introduction
The pipe jacking process consists of transmitting a horizontal force from a vertical
concrete thrust block by means of high capacity hydraulic jacks and hydraulic
pumping units. The pipe is jacked directly into the ground from a jacking pit to a
receiving pit.
This method statement will provide the details of materials, plant & machinery,
manpower and procedure.

2.0 Material
All construction materials shall be approved by consultant and shall be refer to the
relevant construction drawing and technical specification. The material needed for
pipe jacking works are as follows:-
a) Vitrified Clay Jacking Pipe (VCJP)
b) Reinforced Concrete Jacking Pipe (RCJP)
c) Entrance Ring with rubber ring
d) Timber Packing
e) Concrete
f) Crusher run
g) Quarry dust
h) H-Beam
i) Bentonite / Polymer
j) Acetylene & Oxygen
k) Traffic Management Set (Permanent)

3.0 Plant and Machinery

Equipment needed for pipe jacking works are as follows: -
4.1 Slurry Method
a) Slurry Machine ((ID/OD: 450mm/610mm)
b) Slurry Machine (ID/OD: 600mm/775mm, 750mm/960mm)
c) Slurry Machine (ID/OD: 750mm/960mm, 900mm/1200mm)
d) Slurry Machine (ID/OD: 1050mm/1350mm)
e) Slurry Machine (ID/OD: 1200mm/1430mm)
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f) Excavator
g) Vibro hammer machine
h) Dump Truck
i) Mobile Crane
j) Backhoe
k) Water pump (Hydraulic / Submersible / Diaphragm)
l) Welding Set (500 Amp)
m) Generator Set (40kVA, 150kVA, 200kVA, 250kVA, 300 kVA)
n) Air Compressor (175 Cfm)
o) Compactor

4.0 Manpower
Manpower needed for each pipe jacking team (1 shift) is as follows:-
5.1 Slurry Method
a) Foreman – 1 person
b) Operator (Slurry TBM) – 1 person
c) Operator (Excavator) – 1 person
d) Operator (Dump Truck) – 3 persons
e) Operator (Mobile Crane) – 1 person
f) Operator (Backhoe) – 1 person
g) Operator (Vibro hammer) – 2 persons
h) Wireman – 1 person
i) Welder – 1 person
j) Worker – 6 persons
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5.0 Construction
6.1 Pipe Jacking Work using Slurry Method
a) After the jacking and receiving pits have been completed, the alignment and
the invert level of every entry portal will be delineated and marked inside the
jacking pit.
b) A steel plate of 50mm thick shall be erected about 1.0m away from the sheet
pile. Formwork shall also be put up to prepare for the casting of the thrust
wall.
c) The thrust wall shall be constructed using Grade 20 ready-mixed concrete.
d) Once the thrust wall is constructed, the hydraulic jacks shall be placed against
the thrust wall in a prefabricated frame.
e) Guide rails, made up of H-beams shall be aligned in accordance to the
alignment and invert level and welded to the sheet piles to form a launching
platform for the slurry shield.
f) Slurry feed and return pumps, slurry lines and the bypass unit shall be set up
and positioned according to the schematic diagram as depicted in Figure 4.

Slurry
Treatment
Tank

Slurry Discharging Pump

Steel Collars
Thrust Block

Hydraulic Jacks

Jacking Frame / Guide Rail

H
Concrete base

Figure 4: Typical Setup of Pipe Jacking System using Slurry Method

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g) A laser theodolite shall be used as a survey and positioning guidance system

and shall be set up in accordance to the alignment and invert level for each
drive.
h) A test run of the system shall be conducted to ensure everything is in good
working condition. Once this is completed, the slurry shield shall be lowered
into the jacking pit and on to the guide rails.
i) Sheet piles at the entry point inside the entrance ring shall either be cut using
an acetylene cutter or lifted up to facilitate the entry of the slurry shield.
j) The operation of the pipe jacking shall commence with the jacking of the
slurry shield into the ground. Once this is completed, the slurry system shall
be closed and the slurry lines shall be disconnected.
k) A jacking pipe (vitrified clay or reinforced concrete) shall then be lowered and
positioned behind the slurry shield and the slurry lines shall be reconnected.
Typically, a thrust ring shall be fitted to the circumference at the end of the
jacking pipe to distribute the thrust force uniformly.
l) Pipe jacking works shall be resumed and the jacking pipe shall be driven
forward into the ground using the hydraulic jacks. Spacer blocks shall also be
used to lengthen the stroke of the hydraulic jacks.
m) The excavated material shall be removed via the slurry circuit to the surface
for subsequent treatment and disposal.
n) Monitoring of the position and heading shall be constant to ensure the drive is
in accordance to the designed line and grade. Necessary adjustments in the
event of any deviations can be made by steering the slurry shield accordingly.
o) Parameters such as the jacking force, advance rates, shield position, charge
and discharge flow rate shall be recorded daily.
p) Bentonite shall be used to lubricate the contact surface between the jacking
pipe and the ground when required. Bentonite also will act as filler to the
overcutting gap between pipe and soil. Bentonite shall be pumped via a
grouting pump to the grouting holes built into the jacking pipe.
q) Timber packers shall be incorporated into each joint between the jacking
pipes to prevent uneven thrust forces that may damage the jacking pipe.
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r) The above steps shall be repeated until the shield reaches the receiving pit.
An opening shall then be created at the exit point using an acetylene cutter or
by lifting the sheet piles and the slurry shield shall be pushed into the
receiving pit for retrieval. The slurry lines and power cables shall be
disconnected and the slurry shield shall be lifted out from the receiving pit
using a mobile crane.
s) The maximum capability of machine is as follows:-

Maximum capability of the

Item TBM Pipe Size (mm)
TBM
1 Rasa DHFS 400 450mm 5 MPa
2 Iseki TCZ 450 450mm SPT N Value <35
3 Rasa DHD 600 600mm, 750mm 12.5 MPa
4 Iseki TCS 600 600mm, 750mm 12.5 MPa
5 Rasa DHD 800 750mm, 900mm 12.5 MPa
6 Iseki TCZ 800 750mm, 900mm 12.5 MPa
7 Rasa DH 1100 1050mm, 1200mm 12.5 MPa
8 Rasa DHD 1200 1200mm, 1350mm 12.5 MPa
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6.0 Environmental, Safety and Health

6.1 Environmental
a) Work shall be carried out complying with Act and Regulation as per
Environmental Risk Assessment.
b) Proper facilities such as designated area and adequate waste containers shall
be provided at construction site for collection and temporary storage of
construction waste / excavated materials.
c) Construction waste such as timber formworks, steel/scrap metal and
excavated materials which can be reused or recycle should be properly
stacked at the designated area.
d) Concrete delivery shall be controlled to minimize spillage. Any concrete
spillage should be allowed to harden and disposed at the approved dumping
ground.
e) A licensed contractor shall be appointed to handle and dispose the
construction wastes/earth surplus to the approved dumping ground.
f) All water discharges which include (but not limited to) surface runoff, toilet or
bentonite slurries shall go through the final filtration facility such as slurry
treatment tank / silt trap and etc prior to discharge into public storm water
drain or any nearby waterways.
g) Any scheduled waste generated at site shall be managed according to
Environmental Quality (Scheduled Waste) Reg.2005.

6.2 Safety and Health

o) Prior to any site excavation a survey of the site shall be carried out to
determine the presence (if any) of any buried cables or services.
p) Warning signs shall be erected at locations of overhead power cables.
q) Relevant traffic warning sign shall be erected at all site excavations.
r) Barricades and ladders shall be provided at pit location.
s) Workers will be equipped with Personnel Protective Equipment (PPE) i.e.
safety helmet and safety boot / safety vest.
t) Pre start-up toolbox meeting will be held and recorded prior to any work on
site.
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u) Adequate water pumping equipment shall be provided to maintain a dry work

place in the pit. Control banks, run-off ditches and side drain shall be
prepared to prevent ingress of water to the pit from flash storm water.
v) Gas checking shall be done prior to man-entry. Hazardous gasses shall be
monitored including sufficient ventilated air.
w) An emergency response plan to be established to ensure workers safety is not
compromised.
x) Regular mechanical checking to all equipment prior to start works to be done.
y) Housekeeping shall be carried out daily to ensure all loose tools and
equipment is properly stored and rubbish to be disposed.
z) Permit to Work (PTW) shall be implemented for all relevant activities as per
requirements.
aa) Work shall be carried out complying with Act and Regulation as per Hazard
Identifications, Risk Assessment and Determining Control (HIRADC).
bb) HIRADC shall be agreed upon by the issuer and receiver, and being
communicated through any suitable means i.e. meeting, toolbox, safety
induction and etc.