Department of Municipal Affairs and Transport

PO Box 20
Abu Dhabi, United Arab Emirates

© Copyright 2016, by the Department of Municipal Affairs and Transport. All Rights
Reserved. This manual, or parts thereof, may not be reproduced in any form without
written permission of the publisher
 NDRC MANUAL

TABLE OF CONTENTS
Table of Contents ............................................................................................................................. i
List of Figures................................................................................................................................. iv
List of Tables ................................................................................................................................... v
Glossary .......................................................................................................................................... vi
Abbreviations & Acronyms ............................................................................................................ ix
1. INTRODUCTION ........................................................................................................................ 1
1.1 Overview ............................................................................................................................. 1
1.2 Purpose and scope ............................................................................................................. 1
1.3 Application of this manual.................................................................................................... 1
2. NON-DISRUPTIVE ROAD CROSSINGS METHODS................................................................. 2
2.1 Non-Steerable soil displacement methods .......................................................................... 2
2.2 Non-steerable soil removal methods ................................................................................... 3
2.3 Horizontal Directional Drilling (HDD) ................................................................................... 5
2.4 Micro tunnelling ................................................................................................................... 7
2.5 Pilot pipe jacking ................................................................................................................. 9
2.6 Manned Pipe Jacking Methods.......................................................................................... 10
2.6.1 Open front pipe jacking techniques ............................................................................ 10
2.6.2 Closed front (full face excavation) pipe jacking techniques ......................................... 11
2.7 New NDRC techniques ..................................................................................................... 13
2.7.1 Easy pipe ................................................................................................................... 13
2.7.2 Direct pipe .................................................................................................................. 14
3. GENERAL REQUIREMENTS FOR NDRC............................................................................... 16
3.1 Overview ........................................................................................................................... 16
3.2 Standards and Codes of Practice ...................................................................................... 16
3.3 Roles and responsibilities .................................................................................................. 16
3.3.1 Client .......................................................................................................................... 16
3.3.2 Consultant .................................................................................................................. 16
3.3.3 Contractor/Sub Contractor.......................................................................................... 16
3.3.4 Road Authority ........................................................................................................... 17
3.3.5 Town Planning Divisions of Department of Municipal Affairs and Transport ............... 17
3.3.6 Utility Agencies........................................................................................................... 17
3.4 Process Map ..................................................................................................................... 17
3.5 Health and safety .............................................................................................................. 19
3.5.1 Concept Stage ........................................................................................................... 19
3.5.2 Preliminary Design Stage ........................................................................................... 19
3.5.3 Pre-Construction Stage .............................................................................................. 20
3.5.4 During Construction Stage ......................................................................................... 20

PAGE I

TOC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

3.6 Environmental requirements .............................................................................................. 23

3.7 Site condition survey ......................................................................................................... 24
3.8 Geotechnical Investigation ................................................................................................ 24
3.8.1 Minimum requirements of the exploratory boreholes .................................................. 25
3.8.2 Geotechnical Ground Model ....................................................................................... 27
4. PROCEDURES FOR UNDERTAKING NON- DISRUPTIVE ROAD CROSSINGS (NDRC) ..... 28
4.1 Overview ........................................................................................................................... 28
4.2 Concept Stage .................................................................................................................. 28
4.3 Preliminary Design Procedures ......................................................................................... 28
4.3.1 Method selection ........................................................................................................ 28
4.3.2 Design drawings......................................................................................................... 47
4.3.3 Hand excavation ........................................................................................................ 47
4.4 Pre-construction stage ...................................................................................................... 48
4.4.1 Design calculations .................................................................................................... 48
4.4.2 Minimum Depth Requirements ................................................................................... 48
4.4.3 Design drawings......................................................................................................... 49
4.4.4 Ground Surface Movement ........................................................................................ 49
4.4.5 Groundwater Control .................................................................................................. 56
4.4.6 Materials and equipment ............................................................................................ 57
4.4.7 Method Statements .................................................................................................... 57
4.4.8 Risk Assessment and Risk Register ........................................................................... 59
4.4.9 Procedure and logistics for obtaining No Objection Certificates .................................. 60
4.5 During Construction........................................................................................................... 60
4.5.1 Monitoring of Surface Movement ................................................................................ 60
4.5.2 Instrumentation Requirements ................................................................................... 62
4.5.3 Equipment Performance Requirements ...................................................................... 63
4.5.4 Grouting of Annular and voids .................................................................................... 64
4.6 After Construction ............................................................................................................. 64
4.6.1 Inspection and testing ................................................................................................ 64
4.6.2 Site clearance and decommissioning ......................................................................... 64
4.6.3 Monitoring/inspection for long term (latent) defects .................................................... 65
4.6.4 QA/QC Methodology .................................................................................................. 65
Cited References ........................................................................................................................... 66
Appendix A: Checklists for submittals ........................................................................................ 67
A.1 Checklist of submittals for approval of the preliminary design ................................................ 67
A.2 Checklist of submittals for approval of construction ............................................................... 68
A.3 Checklist of Potential H&S Hazards & Risks .......................................................................... 69
A.4 Checklist of Authorities for NOCs .......................................................................................... 70
A.5 Checklist of QAQC Issues ..................................................................................................... 71

PAGE II

TOC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

A.6 Checklist of Post-Construction Checks .................................................................................. 72

Appendix B: Forms and Examples of Application for NDRC Works.......................................... 73
B.1 Required forms and examples of letters ................................................................................ 73
Appendix C: Checklists for monitoring during construction ..................................................... 83
C.1 Daily Requirements ............................................................................................................... 83
Appendix D: Checklists for monitoring after construction ........................................................ 84
D.1 After Construction.................................................................................................................. 84
Appendix E: Tunnelling and Pipe Jacking ................................................................................... 85

PAGE III

TOC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

LIST OF FIGURES

Figure 1: Impact moling/soil displacement hammer (Speedy Co.) ..................................................... 2

Figure 2: Pipe ramming diagram (Earth Tool Company, LLC) ........................................................... 2
Figure 3: Impact moling (Speedy Co.) ............................................................................................... 3
Figure 4: Auger head ......................................................................................................................... 4
Figure 5: Auger boring (Nickol Boring Co.) ........................................................................................ 4
Figure 6: Process of the horizontal directional drilling (Gateway Directional Drilling Co.) ................... 6
Figure 7: Micro tunneling (http://www.osw.com.au) ........................................................................... 7
Figure 8: Slurry shield micro tunneling (Iseki Poly-Tech, Inc.-Japan) ................................................. 8
Figure 9: Stages of pilot pipe jacking with auger soil removal (PRG Metro Co.)................................. 9
Figure 10: Backactor shield (The Pipe Jacking Association) ............................................................ 10
Figure 11: A cutter boom shield (The Pipe Jacking Association) ..................................................... 11
Figure 12: Open front pipe jacking ................................................................................................... 11
Figure 13: Earth pressure balance machine (EPBM)(Herrenknecht AG) ......................................... 12
Figure 14: A slurry shield (full face excavation) pipe jacking machine (Herrenknecht AG) ............... 12
Figure 15: Easy pipe Method ........................................................................................................... 14
Figure 16: Direct pipe method (Herrenknecht AG) ........................................................................... 15
Figure 17: Process Map of NDRC ................................................................................................... 18
Figure 18: Pipe jacking worksite and shaft....................................................................................... 19
Figure 19: The different cutting heads (JUN Engineering Co., Ltd.) ................................................. 32
Figure 20: Principles of a hydraulic mucking boring machine (Herrenknecht AG) ............................ 33
Figure 21: Locating systems (Grundodrill co.)................................................................................. 37
Figure 22: Basic components of rig (Grundodrill co.) ....................................................................... 38
Figure 23: Slanted face Drill Bits (Ref.1) .......................................................................................... 41
Figure 24: Modified Slanted face Drill Bits (Ref.1) ........................................................................... 41
Figure 25: Modified Slantedface Drill Bits ........................................................................................ 42
Figure 26: Rock Drill Bits (Ref. ........................................................................................................ 42
Figure 27: Tri-Cone Rock Bits ......................................................................................................... 43
Figure 28: Working shafts ................................................................................................................ 45
Figure 29: Hand Excavation ............................................................................................................ 48
Figure 30: Idealized Settlement Trough Over Tunnel....................................................................... 51
Figure 31: Settlement expressed in terms volumes. ........................................................................ 52
Figure 32: Example of Finite Element Settlement Analysis for Twin Circular Tunnels under Pile
Foundations (www.nastt.org ) .......................................................................................................... 53

PAGE IV

TOC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

LIST OF TABLES

Table 1: Required Soil Parameters .................................................................................................. 26

Table 2: NDRC Methods related to soil types .................................................................................. 30
Table 3: Different applications of NDRC .......................................................................................... 31
Table 4: NDRC methods with typical pipe size, length and accuracy ............................................... 34
Table 5: Rigs types and specification .............................................................................................. 39
Table 6: Drill Bit Types and Application Guidelines (Courtesy DCCA) ............................................. 40
Table 7: Operational risks in HDD installations (Baumert and Allouche 2003) ................................. 44
Table 8: Design of working shafts in Dry ground(Source: Reference- 3) .......................................... 45
Table 9: Design of working shafts in wet ground (Source: Reference - 3) ........................................ 46
Table 10: Shaft Dimensions............................................................................................................. 46
Table 11: Shaft sizes ....................................................................................................................... 47
Table 12: Risk Summary for Typical NDRC Methods ...................................................................... 59
Table 13: Type of record for NDRC projets...................................................................................... 62

PAGE V

TOC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

GLOSSARY
Specialized terms, abbreviations and acronyms frequently used in this manual are listed and
defined below. Where a term, abbreviation or acronym is defined in another Department of
Transport Manual, that definition is applied to this manual by reference.
Auger Boring: Method for forming a bore, usually from a drive pit, by means of a rotating cutting
head. Spoil is removed back to the drive pit by helically wound auger flights rotating in a steel
casing. The equipment may have limited steering capability. See also Guided Auger Boring.
Back Reamer: Cutting head attached to the leading end of a drill string to enlarge the pilot bore
during a pull-back operation to enable the product pipe to be installed.
Bore: Void which is created to receive a pipe, conduit or cable.
Cased Bore: Bore in which a pipe, usually a steel sleeve, is inserted simultaneously with the
boring operation. Usually associated with auger boring or pipe jacking.
Casing: Pipe to support a bore. Usually not a product pipe.
Cutting/Cutter Head: Tool or system of tools on a common support that excavates at the face of a
bore. Usually applies to mechanical methods of excavation.
Directional Drilling: Steerable method for the installation of pipes, conduits and cables in a
shallow arc using a surface launched drilling rig. In particular, the term applies to large scale
crossings in which a fluid filled pilot bore is drilled without rotating the drill string, and this is then
enlarged by a wash over pipe and back reamer to the size required for the product pipe. The
required deviation during pilot boring is provided by the positioning of a bent sub.
Drill Bit/Head: Tool which cuts the ground at the head of a drill string, usually by mechanical
means.
Drilling Fluid/Mud: Mixture of water and usually bentonite or polymer continuously pumped to the
cutting head or drill bit to facilitate the removal of cuttings, stabilise the bore, cool the head and
lubricate the passage of the product pipe. In suitable ground conditions water alone may be used.
Drill String/Stem: The total length of drill rods/pipe, bit, swivel joint, etc. in a bore.
Drive/Entry Shaft/Pit: Excavation from which trenchless technology equipment is launched for the
installation or renovation of a pipeline, conduit or cable. It may incorporate a thrust wall to spread
reaction loads to the ground.
Earth Pressure Balance (EPB) Machine: Type of microtunnelling machine in which mechanical
pressure is applied to the material at the face and controlled to provide the correct counter-balance
to earth pressure in order to prevent heave or subsidence. The term is usually employed where the
pressure originates from the main jacking station in the drive shaft or to systems in which the
primary counter-balance to the earth pressures is supplied by pressurised drilling fluid or slurry.
Face Stability: Stability of the excavated face of a tunnel or pipe jack.
Grouting: Method of filling voids, usually with cementitious grout.
Guided Auger Bore: Method of auger boring in which the guidance mechanism actuator is sited in
the drive shaft. The term may also be applied to those auger boring systems with rudimentary
articulation of the casing near the cutting head activated by rods from the drive shaft.
Guided Boring: See Guided Drilling.
Guided Drilling: Method for the installation of pipes, conduits: and cables using a surface-
launched drilling rig. A pilot bore is drilled using a rotating drill string and is then enlarged by a back
reamer to the size required for the product pipe. The necessary deviation during the pilot boring is
provided by a slanted face to the drill head, an asymmetric drill head, eccentric fluid jets or a
combination of these, usually in conjunction with a locator.

PAGE VI

GLOSSARY FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Guide Rail: Device used to support or guide, first the shield and then the pipe within the drive
shaft during a pipe jacking operation.
Heaving: Process in which the ground may be displaced causing a lifting of the ground surface.
Horizontal Directional Drilling (HDD): See Directional Drilling.
Impact Moling: Method of creating a bore using a pneumatic or hydraulic hammer within a casing,
generally of torpedo shape. The term is usually associated with non-steered or limited steering
devices without rigid attachment to the launch pit, relying upon the resistance of the ground for
forward movement. During the operation the soil is displaced, not removed. An unsupported bore
may be formed in suitable ground, or a pipe drawn in, or pushed in, behind the impact moling tool.
Cables may also be drawn in.
Impact Ramming: See Pipe Ramming.
Jacking Force: Force applied to pipes in a pipe jacking operation.
Jacking Pipes: Pipes designed for use in a pipe jacking operation.
Jacking Shield: Fabricated steel cylinder from within which excavation is carried out, either
manually or by mechanical means. Incorporated within the shield are facilities for controlling line
and level.
Launch Pit: As for drive pit but more usually associated with launching an impact moling or similar
tool.
Locator: An electronic instrument used to determine the position and strength of electromagnetic
signals emitted from a transmitter sonde in the pilot head of a boring system, in an impact moling
tool or from existing underground services that have been energised. Sometimes referred to as a
Walkover System.
Microtunnelling: Method of steerable remote control pipe jacking to install pipes of internal
diameter less than that permissible for man-entry. In North America the term is used to describe
remote control continuous pipe jacking in all diameters.
Pilot Bore: First, usually steerable, pass of any boring operation that later requires backreaming or
other enlargement. Most commonly applied to guided drilling, directional drilling and 2-pass
microtunnelling systems.
Pipe Jacking: Method for directly installing pipes behind a shield machine by hydraulic or other
jacking from a drive shaft such that the pipes form a continuous string in the ground.
Pipe Ramming: Non-steerable method of forming a bore by driving a steel casing, usually open
ended, with a percussive hammer from a drive pit. The soil may be removed by auguring, jetting or
compressed air. In appropriate ground conditions a closed casing may be used.
Product Pipe: Permanent pipeline for operational use.
Pull-Back: That part of a guided drilling or directional drilling operation in which the drill string is
pulled back through the bore to the entry pit or surface rig, usually installing the product pipe at the
same time.
Reception/Exit Shaft/Pit: Excavation into which trenchless technology equipment is driven and
may be recovered during the installation or renovation of a product pipe, conduit or cable.
Rod Pushing: Method of forming a pilot bore by driving a closed pipe head with rigid attachment
from a launch pit into the soil that is displaced. Limited steering and monitoring capability may be
provided, usually in conjunction with a locator.
Subsidence: Process in which the ground may be displaced causing a settlement at the surface.
Target Shaft/Pit: See Reception/Exit Shaft/Pit.
Thrust Pit: See Drive Pit.

PAGE VII

GLOSSARY FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Trenchless Technology: Methods for utility and other line installation, rehabilitation, replacement,
renovation, repair, inspection, location and leak detection, with minimum excavation from the
ground surface.
Uncased Bore: Self-supporting bore without a lining or inserted pipe, whether temporary or
permanent.
Walkover System: See Locator.

PAGE VIII

GLOSSARY FIRST EDITION -DECEMBER 2016

NDRC MANUAL

ABBREVIATIONS & ACRONYMS

DMAT Department of Municipal Affairs and Transport

HDD Horizontal directional drilling
NDRC Non Disruptive Road Crossings
NOC No Objection Certificate
ROW Right of Way
UPC Urban Planning Council

PAGE IX

ABBREVIATIONS & ACRONYMS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

1. INTRODUCTION
1.1 Overview
In 2010, the Abu Dhabi Department of Transport commenced with the “Unifying and Standardizing
of Road Engineering Practices” Project. The objective of the project was to enhance the
management, planning, design, construction, maintenance and operation of all roads and related
infrastructures in the Emirate and ensure a safe and uniform operational and structural capacity
throughout the road network.
To achieve this objective a set of standards, specifications, guidelines and manuals were
developed in consultation with all relevant authorities in the Abu Dhabi Emirate including the
Department of Municipal Affairs and Transport (DMAT) and Urban Planning Council (UPC). In
future, all authorities or agencies involved in roads and road infrastructures in the Emirate shall
exercise their functions and responsibilities in accordance with these documents. The purpose,
scope and applicability of each document are clearly indicated in each document.
It is recognized that there are already published documents with similar objectives and contents
prepared by other authorities. Such related publications are mentioned in each new document and
are being superseded by the publication of the new document, except in cases where previously
published documents are recognized and referenced in the new document.

1.2 Purpose and scope

The purpose of this Manual is to provide specific procedural guidance on Non Disruptive Road
Crossings (NDRC) for staff of the Department of Municipal Affairs and Transport (DMAT) and
other concerned government highway agencies (Municipalities), designers, Contractors and utility
agencies.
However, due to the specific technical nature of this type of construction, the Manual also provides
guidelines for the specialized Contractors experienced in the utilization of plant and equipment
fabrication, in order to select the most appropriate method for such operations.
The Manual is specifically aimed at recognizing local conditions related to the present legal
framework, existing geotechnical conditions and practices presently employed by the local
construction industry which perform successfully. However, global best practices are studied and
improvements recommended as appropriate.
The overall objective of this Manual is to provide guidelines for the construction of NDRC which do
not result in either short term or long term surface movement, nor in road collapse due to drilling
mistakes or obstacles.

1.3 Application of this manual

The Manual is intended for use by Department of Municipal Affairs and Transport (DMAT)and can
be used by other road agencies of the Emirate (Municipalities) in specifying the requirements and
approval procedures for NDRC work.
It is however also to be used by utility agencies, designers and Contractors in selection and design
of NDRCs which will cross the Main roads under jurisdiction of the Abu Dhabi DMAT Non
Disruptive Road Crossings Methods.
In this Chapter more detailed information is given on various methods of NDRC.

PAGE 1

01 INTRODUCTION FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

2. NON-DISRUPTIVE ROAD CROSSINGS METHODS

In this chapter, more detailed information is given on various methods of NDRC.

2.1 Non-Steerable soil displacement methods

A number of soil displacement methods exist. Impact moling or sometimes called soil displacement
hammer is one of the more common methods. The method involves driving a moling or hammering
tool with a tapered head through the ground (see Figure 1). The hammering tool can either work
with compressed air or hydraulically and it displaces the soil as it moves through the ground.
The piping or cable material is either pushed directly behind the tool or, in stable soil conditions it
may be pulled in afterwards through the cavity made by the tool.
Pipe ramming with a closed pipe is another soil displacement method often used. Like impact
moling or soil displacement hammer it uses compressed air or hydraulically activated ramming
device to push a closed steel pipe through the soil (see Figure 2).

Figure 1: Impact moling/soil displacement hammer (Speedy Co.)

Figure 2: Pipe ramming diagram (Earth Tool Company, LLC)

Advantages and disadvantages of the non-steerable soil displacement technique are briefly set out
below.

PAGE 2

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Advantages
 Generally very quick and easy to use and thereby also very cost effective. Moles or
hammering tools are available for many soil conditions and can penetrate soft rock.
 The methods require relatively small entry and exit pits. When installing the pipe or cable
directly behind the hammering tool, surface settlements are minimised.
Disadvantages
 The methods require that the soil is displaceable and surface heave may occur if sufficient
soil cover is not available above the tunnel.
 A minimum cover of 10 times the outer pipe or hammer diameter is recommended.
 Pipelines installed in this manner are necessarily straight as there is no steering
mechanism.
 The alignment of the tunnel can be influenced by the soil conditions, especially obstructions
or stratifications thatmay alter the direction of the tool or pipe.
 Installation of pipelines that require a precise alignment should not be undertaken using
non-steerable methods.
 The poor alignment accuracy also reduces the typical lengths for which the methods are
appropriate, and safe distances to other structures or utilities must be maintained.

Figure 3: Impact moling (Speedy Co.)

2.2 Non-steerable soil removal methods

Pipe ramming can also be carried out with an open pipe end and thereby without soil
displacement. Instead the soil is either removed during the driving of the pipe or afterwards. Soil
removal is typically undertaken using water jetting, flushing, compressed air or mechanically, for
example with an auger. These are some points to consider with this method:
 Up to 2000 mm diameter with max length 80 m.
 With the use of an auger, a cutting head can be attached to the head giving an improved
method for application in harder soils. Examples of pipe ramming and auger boring are
shown in Figures 4 and 5.
 The pipe material is usually a steel casing or sleeve pipe inside which the product pipe or
cables can be pulled or pushed after soil removal.

PAGE 3

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 Entry and exit pits are required for this method, where the entry pit may need to be very
long in order to accommodate the pipe and auger sections along with the ramming or
jacking device.
 Below ground water levels the methods must be used with caution or dewatering must be
initiated.
 Pipe ramming may be achieved if the pipe can be driven completely through before soil
removal and the soil "plug" inside the pipe is sufficiently stable to withstand the ground
water pressure while ramming.

When auger boring, the auger may become flooded underground water levels giving way for
excessive soil loss and major surface settlement. Some manufacturers have designed a sluice
system for the auger to counter this effect.

Figure 4: Auger head

Figure 5: Auger boring (Nickol Boring Co.)

PAGE 4

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Advantages
 These methods, like the other non-steerable methods, are generally less expensive than
similar sized steerable methods due to the need for fewer and simpler equipment and
machinery.
 The method can be used for significantly larger pipe sizes compared to displacement
techniques (2000 mm diameter or larger). The larger diameter pipelines are typically stiffer
and less susceptible to altering direction during installation.
Disadvantages
 In swelling or very plastic soils the methods may not be possible.
 Pipe ramming cannot be done in rock. However with the use of an auger, a cutting head
can be attached to the head giving an improved method for application in harder soils.
 Loss of face stability when tunnelling below groundwater level can lead to construction
difficulties and even failure to complete the tunnel. The same difficulties with directional
control exist as for the non-steerable methods.

2.3 Horizontal Directional Drilling (HDD)

Horizontal direction drilling is likely to be the most widely used NDRC method, due to the extreme
versatility in uses. The method can be conducted from the ground surface without the need of
deep entry and exit shafts.
 The installation size can be anywhere from small diameter single cable crossings up to
1200 mm diameter pipes. Drilling distances can reach as much as 1500-1800 m in a single
drill - longer drills have been achieved using intersecting methods.
 The method requires a HDD rig capable of applying torque and thrust to drill a drilling pipe
through the ground. A steerable drilling head, specially designed for the soil conditions, is
situated at the front end of the pipes.
 Directly behind the drill head is a probe or transmitter sending signals through the ground.
These signals can be tracked from the ground surface, thereby determining the position
and depth of the drill. The direction of the drill can be altered by the asymmetrical steering
face of the drill head.
 After completing the drill, the bore hole is expanded to the required size by attaching
reamers to the drill pipe and pulling back in one or more steps. The desired pipeline is
typically attached directly behind the final reamer.
 Drilling fluid (typically a bentonite suspension) is continuously pumped into the borehole in
order to remove the spoils and support the borehole. An example of a HDD setup is shown
in Figure 6.
 The reamer is generally larger than the pipeline being installed creating an overcut or
annular space surrounding the pipeline through which the soil and drilling fluid mixture can
escape.

PAGE 5

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

NDRC MANUAL

Figure 6: Process of the horizontal directional drilling (Gateway Directional Drilling Co.)

Advantages
 The wide size range and the ability to undertake HDD without large entry and exit pits and
without groundwater lowering are very clear advantages of this method.
 The direction of the drill can be altered while drilling making it possible to install a curved
pipeline. This can be a great advantage when manoeuvring around existing structures or
other utilities.

Disadvantages
 The achievable alignment accuracy may be insufficient for pipelines that require high
precision alignment.
 Maximum pipe diameters are limited to about 1200mm.
 Sudden changes in soil type from say clay to sand can lead to loss of control of fluid
pressure which in turn can lead to collapse of the soil annulus around the pipe.
 In certain situations, the pipe may become stuck leading to loss of the HDD string.

PAGE 6

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

2.4 Micro tunnelling

Micro tunnelling is a name generally associated to unmanned pipe jacking methods for pipes
smaller than 1000 mm diameter. However larger diameter machines and equipment are readily
used and it would be more appropriate to use the term micro tunnelling for any unmanned pipe
jacking using a steerable tunnelling machine.

Figure 7: Micro tunneling (http://www.osw.com.au)

In micro tunnelling the pipeline is installed by pushing (jacking) the pipes forward from the starting
shaft as the tunnelling machine excavates the soil at the front of the pipeline. The excavated soil
can be removed through the already laid pipes by various methods. Examples of this are auger soil
removal or slurry shield micro tunnelling as shown in Figures 7 and 8.
In the auger method the excavated soil is removed mechanically with the continuous line of
augers. In the slurry shield method the excavated soil is mixed with a bentonite slurry suspension
and pumped out of the pipeline. After being pumped out the soil is settled or separated from the
slurry in a tank or separation unit and the slurry is reused.
When working below ground water levels the auger soil removal may pose the same problems,
where the auger may flood and give way for excessive soil loss. The slurry shield micro tunnelling
machine is typically designed with a pressurized bulkhead, where slurry is pumped at a sufficient
pressure to stabilizes any loose soil and balance ground water pressure.
The tunnelling machine can be controlled by an operator outside the pipeline. The alignment is
usually controlled by laser or by gyroscope and water level. The line is typically straight, but using
gyroscope or specialized surveying equipment and short pipe lengths, curved tunnels can be
constructed.
Piping materials must be designed to withstand the jacking forces acting on them under
installation. Concrete is often used as piping material along with fibreglass or composites with
concrete and fibreglass. Polymer materials especially polymer concretes are becoming more
common due to their strength and corrosion resistance.

PAGE 7

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

NDRC MANUAL

Figure 8: Slurry shield micro tunneling (Iseki Poly-Tech, Inc.-Japan)

Advantages
 Micro tunnelling works in almost all soil conditions and cutting heads can be modified to
deal with weak rocks.
 Pipes of up to 2000mm diameter can be installed and can be constructed to a high degree
of accuracy which makes the technique suitable for pipelines that require precision in
alignment or gradient.

Disadvantages
 Obstacles (large rocks/boulders or other materials) may stop machines not designed for
cutting through these materials. In such cases there may be no other solution, than to
excavate from the surface to remove the obstacle. If this is not possible, the tunnel and
machine may have to be abandoned.

PAGE 8

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 Working in mixed face conditions can be problematic, particularly where slurry support is
used below groundwater as the slurry pressure may be difficult to control. Loss of
slurry/face support can lead to instability and ravelling leading to large surface settlements
and, in the extreme case, abandonment of the pipe and machine.
 Micro tunnelling is generally more expensive than many of the other NDRC methods,
requiring relatively large entry and exit shafts and more advanced equipment and materials.

2.5 Pilot pipe jacking

This method is basically a variation of the non-steerable auger boring method. In this method
however a steerable pilot pipe is initially jacked or drilled through the soil. The alignment of the pilot
pipe is controlled by laser and a small camera at the head of the pipe.
After installing the pilot pipe an open steel pipe with an auger for soil removal is attached to the
pilot pipe and pushed/jacked through. The steel pipe is usually just used as a sleeve for the
product pipe which is pulled in afterwards.
Variations of the method include attaching a reamer followed by a plastic pipeline and pulling these
through in a similar manner as HDD.
A-

B-

C-

Figure 9: Stages of pilot pipe jacking with auger soil removal (PRG Metro Co.)

Advantages
 The method is very accurate(unlike the non-steerable auger boring method). The pilot pipe
can generally be installed to an accuracy of +/- 20 mm (in both directions) and the steel
sleeve pipe will typically follow this line with little deviation.

PAGE 9

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 The technique is a relatively cheap method of achieving a pipeline to a high precision in

alignment and gradient.

Disadvantages
 Large rocks or differences in soil structure surrounding the pilot pipe can give problems.
 Ground water may give some of the same problems described in sections on non-steerable
auger boring and micro tunnelling.

2.6 Manned Pipe Jacking Methods

Manned pipe jacking methods are very similar to the techniques given as micro tunnelling – the
difference is basically that the manned methods are sufficiently large in diameter to accommodate
workers inside the pipeline.
A wide range of tunnelling machines designed for varying types of soil and groundwater conditions
exist. The machines can generally be divided into open or closed face machines – the selection is
dependent on the soil conditions and the required support necessary for stability of the soil.

2.6.1 Open front pipe jacking techniques

Open faced pipe jacking can be done in stable soil conditions with little or no ground water inflow.
The method consists of a tunnelling machine with an open front, where soil is excavated
mechanically and transported with conveyor belt and/or buckets out of the pipeline. Examples of
open front pipe jacking are shown in Figure 10 and Figure 11.

Figure 10: Backactor shield (The Pipe Jacking Association)

PAGE 10

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Figure 11: A cutter boom shield (The Pipe Jacking Association)

Figure 12: Open front pipe jacking

Working below ground water levels, pressure may be applied to the front using a chamber lock
system as shown in Figure 12. The pressurized front allows excavation without losing soil stability
due to ground water infiltration. This will generally only work in cohesive soils or rock - in very
loose soils, an open front is very questionable.

2.6.2 Closed front (full face excavation) pipe jacking techniques

In loose soils or conditions with high ground water levels, a closed front machine may be used.
Closed front machines can be of the slurry shield type as described in Section 4.3.1.1 on micro
tunnelling or alternatively an earth pressure balance machine (see Figure 13).
The slurry shield tunnelling machine works as described previously with a bentonite slurry
suspension that is mixed with the excavated soil and pumped out of the pipeline. An example of
this type of machine is shown in Figure 14.

PAGE 11

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Figure 13: Earth pressure balance machine (EPBM)(Herrenknecht AG)

Figure 14: A slurry shield (full face excavation) pipe jacking machine (Herrenknecht AG)

Advantages
 Manned pipe jacking methods have the general advantage that access to the driving front
is relatively easy - making it possible to remove obstacles (larger rocks/boulders etc.) with
manual methods.
 Open front machines obviously have the most direct access, where closed front machines
may need to be designed with access gates.
Disadvantages
 There are many health and safety issues associated with manned pipe jacking, not least
the need to work in confined spaces with the dangers of face collapse and groundwater
inundation.
 Detailed and robust health and safety procedures dealing specifically with the hazards
related to this construction method need to be implemented for all manned pipe jacking
operations.
 Tunnelling equipment is large and expensive and requires relatively large site areas for the
launch and reception pits.

PAGE 12

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

2.7 New NDRC techniques

NDRC techniques continue to evolve and new techniques are constantly being trialled and
implemented to overcome some of the disadvantages of conventional techniques or provide faster,
cheaper installations. Two such techniques are the “Easy Pipe” and the “Direct Pipe” methods

2.7.1 Easy pipe

As shown inFigure 15,this technique combines conventional micro tunnelling with an innovative
method of using the jacking pipes to help install the permanent pipe. Once the tunnel has been
bored, the micro tunnelling machine is removed and the permanent pipe isattached to the installed
jacking pipes.
The jacking pipe segments (which are bolted together) are pulled back through the tunnel, pulling
the permanent pipe with them. In this way, the permanent pipe is installed quickly and easily and
the jacking pipe segments can be re-used for the next project.
Easy Pipe installation requires a micro tunnelling unit to be prepared and assembled in the launch
pit. The cutter head is launched and guided in the conventional micro tunnelling way along a
planned alignment.
The difference between the jacking pipes used by Easy Pipe and conventional ones is that the
special design allows them to be used as jacking pipes in the forward direction while allowing them
to be retracted from the completed bore to pull in the product pipe.
This is because the joints between the jacking pipe sections bolt together with a design that will
withstand thrust and pullback forces of up to 6,300 kN (630 tons).The close proximity of the jacking
pipes' outer wall to the bore wall also avoids the potential for collapse of the bore in unstable
ground formations.
After the cutter head has reached the target pit, it is separated from the jacking pipe string and
replaced by a specially designed connection pipe that also connects to the product pipe. The
jacking pipes are then pulled back using the bi-directional jacking frame, simultaneously pulling the
product pipe into position. In the launch pit the individual jacking pipes are successively removed
along with all other equipment until the product pipe arrives at the launch shaft.
The connection pipe and jacking frame are removed from the pit leaving the product pipe in place
to be finally connected to the remainder of the pipeline on either side of the obstacle(s) crossed.

PAGE 13

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Figure 15: Easy pipe Method

2.7.2 Direct pipe

The direct pipe technique is a hybrid of the HDD and micro tunnelling methods. As shown on
Figure 16,in this technique, the micro tunnelling machine is pushed in to the ground using a jacking
frame that grabs directly on to the final production pipe and uses this to push the micro tunnel
machine forward. In this way, once the tunnel is bored, there is no need for a secondary production
pipe installation process as the production pipe is installed directly as part of the tunnelling
operation. Installation of the pipe is limited by the thrust that can be applied to the pipe without
causing damage and the need for sufficient space to lay the pipe out behind the micro tunnel
machine prior to commencing boring.

PAGE 14

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Figure 16: Direct pipe method (Herrenknecht AG)

Advantages
 Single-step method leads to rapid installation of product piping and pipelines
 No time needed for coupling pipes (Microtunneling) or drill rods (HDD)
 Pipeline can be installed pre-welded and already tested
 Costly shaft construction unnecessary - instead, only simplified surface entry and exit pits
are required
 One-pass work phase of operation for excavation and pipeline installation
 Inclines and gradients as well as curved drilling profiles can be negotiated precisely
 Ideal method for sea outfalls with access from one side only
 Pipe Thruster enables both tunneling machine and pipeline to be withdrawn, for example
for cutting tool retooling operations in inaccessible, low-diameter areas
 Cone crusher removes obstacles as they occur
Application options
 Pipeline laying from construction pit to construction pit
 Pipeline laying from construction pit to shaft
 Pipeline laying from construction pit to destination point, for example water course beds
Range of application
 Pipeline diameter: 28 (711mm)–36” (914mm),38” (965mm)–44” (1117mm),46” (1168mm)–
52” (1320mm) –54” (1372mm)–60” (1524mm).
 Excavation diameter 805 / 990 mm 1,140 mm 1,325 mm 1,540 mm
 Maximum pipeline / drilling length 300 m 700 m 1,200 m 1,400 m
 Geology: -Clay, Silt, Sand, Gravel, Cobbles, Boulders, Rock (up to 150 MPA)
 Pipe material: - Steel
 Coating material: - PE, PP, GRP, FBE

PAGE 15

02 NON-DISRUPTIVE ROAD CROSSING METHODS FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

3. GENERAL REQUIREMENTS FOR NDRC

3.1 Overview
This chapter provides general information for undertaking Non Disruptive Road Crossings
including an overview of the parties involved and their roles and responsibilities.
The chapter further covers the general requirements for environment, health and safety along with
requirements for site survey and geotechnical investigations.

3.2 Standards and Codes of Practice

A number of local and international Standards and Codes of Practice along with guidelines and
specifications have been sourced during the process of creating this manual. The documents and
information are listed in the (cited reference) sections were chosen as they were typically viewed
as being ‘best practice’ internationally, in the field of NDRC and trenchless technology.
Additional information on methods and equipment can be found in these or from technical
associations such as:
 International Society of Trenchless Technology, ISTT - www.istt.com
 Pipe Jacking Association (UK) - www.pipejacking.org
 North American Society for Trenchless Technology, USA - www.nastt.org

3.3 Roles and responsibilities

This section describes typical roles and responsibilities of the parties involved in undertaking
NDRC works. The specific responsibilities and authorities of the different parties involved can vary
from project to project depending on the contract agreements between the parties.
Road crossings and in particular NDRC works are typically contracted as part of a main project
involving installation of utility lines in an area, along roads, etc.

3.3.1 Client
The Client is the owner of the pipeline or cable to be installed. The overall responsibility for the
installation and operation of the pipeline or cable is that of the Client.
The Client can delegate certain responsibilities such as design and calculations along with the
responsibility for safeguarding of the road to others through contract agreements.

3.3.2 Consultant
The Consultant is typically hired by the Client to design, tender and supervise the overall project.
The Consultant will typically undertake preliminary site and soil investigations to collect information
on existing utilities, surface and sub-surface constructions during the design stage. The consultant
will supervise the installation and NDRC work during construction.

3.3.3 Contractor/Sub Contractor

The Contractor or, if delegated, the specialist Sub Contractor is responsible for the correct
installation of the pipeline or cable in accordance with the specifications.

PAGE 16

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

The Contractor/Sub Contractor is responsible for obtaining approval from the Road Authority prior
to commencement of the NDRC work. Approval is only given after Submitting a complete and
acceptable method statement including all required information in accordance with this manual.

3.3.4 Road Authority

The Road Authority (Department of Municipal Affairs and Transport - DMAT) is responsible for
granting approval of any NDRC work. The Road Authority's main interest is in protecting their
assets - the road, footpaths, structures, etc. from any harm, settlement or heave resulting from the
NDRC work which lies within the highway Right of Way.

3.3.5 Town Planning Divisions of Department of Municipal Affairs and

Transport
Abu Dhabi Town Planning will give initial approval and assign a corridor that the Client may use.
This is done only after checking with, and obtaining NOCs from the Road Authority, other Utility
Agencies and any other relevant authorities.
After giving approval and assigning a corridor Abu Dhabi Town Planning will refer to the Road
Authority for final approval of the NDRC work.

3.3.6 Utility Agencies

Other utilities agencies may be affected by the NDRC if their pipelines or cables are located near
the proposed NDRC. The Contractor will need to obtain No Objection Certificates (NOC's) from all
the concerned utilities agencies. These may be accompanied with certain requirements or
restrictions concerning the NDRC.

3.4 Process Map

When following the procedure below, it is imperative that the Consultant follow the guidance
contained in this Manual, and if any of the processes are not completed to the DMAT’s satisfaction,
then the relevant stage will not be approved.
The process of undertaking NDRC work involves a five part approval process. Important points for
the Consultant to consider:
 The stages are illustrated in Figure 17below showing the main activities and responsibilities
in each stage.
 Detailed information and requirements of the various activities can be found the
subsequent sections of this manual.
 Check lists of required submittals to the Road Authority are given in Appendix A.
 The estimated processing times in the approval stages are based on complete and full
submittals. Any missing information may result in prolonged processing times.
 Anywhere along the process factors may arise that will require the planned NDRC to be
revised and the process to be returned to an earlier stage.
All applications for approval with the DMAT must be submitted using the No Objection Certificate -
Right of Way (NOC-ROW) online system. Please refer to the DMAT website for the latest
information on this subject.

PAGE 17

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Responsible Activity Details and information to be acquired

PHASE 1 Concept Stage
Client/ Map of intended NDRC Location/vicinity
Consultant Size (diameter) and level

Approval process - part 1

Submit to Abu Dhabi Town Planning for approval of corridor and NOC Expected processing time:
4-6 weeks
PHASE 2 Preliminary design
Client/ Geotechnica Geotechnical Assessment (Key stage 2) according to Manual for
Consultant Geotechnical Investigation and Geotechnical Design including
Ground Investigation Factual and Interpretative Reports.
Site investigation Surface and underground structures
Other utilities Location and type
Drawings Line, level, diameter
Work area with working shaft locations and sizes
Method selection Suggested method and equipment
Requirements for accuracy, material, etc.

Approval process - part 2

Submit to Road Authority for preliminary approval of design Expected processing time:
Check list of submittals required is given in appendix A. 2-3 weeks
PHASE 3 Pre-construction Stage
Contractor/ Design calculations Pipe strength
Sub Contractor Working shafts
Jacking and friction forces
Surface settlement/heave
Design drawings Plans and profiles of the intended line
Working area plans showing placement of equipment and
materials.
Traffic diversion plans
Details of working shafts
De-watering system design
Materials and equipment Lists of all in use
Method statement Contractor name
List of personnel with qualifications
Sequencing and procedure of work
Ground water control and dewatering
Safety procedures
Environmental assessment
Risk assessment
NOC From all relevant utilities and authorities
Letters of undertaking From Client and Consultant

Approval process - part 3

Submit to Road Authority for approval of construction Expected processing time:
List of submittals required is given in Appendix A 3-4 weeks
PHASE 4 Construction
Contractor/ Site condition survey Surrounding surfaces and structures
Sub Contractor Pre construction photos
Monitoring Setup and monitoring of surface movement
QA/QC Documentation in accordance with QC plan

PHASE 5 After construction

Monitoring Surface movement - monthly reports

Figure 17: Process Map of NDRC

PAGE 18

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

3.5 Health and safety

All parties involved in NDRC work have an important role in establishing safe working
conditions.During planning and design all foreseeable health and safety risks likely to arise shall
be identified and taken into consideration in the design. All health and safety information known to
the Client, Consultant or designer must be given to the Contractor prior to undertaking the
NDRCwork.

Figure 18: Pipe jacking worksite and shaft

The Contractor must ensure that prior to commencement of any project, a Health and Safety Plan
is prepared which covers the specific requirements of the project. This plan shall be submitted
prior to approval of construction along with the Method Statement, and approved by the relevant
Consultant (usually the Engineer).
General requirements for Environment Health and Safety must comply with the DOT-M-08 EHS
Manual for Road Projects. All issues relating to EHS must be raised and addressed along all
stages of the project.

3.5.1 Concept Stage

During this phase, it is important for the design team to establish the route of the NDRC to
minimise the risks to safety for any persons working on the construction.
When submitting the relevant design information to Abu Dhabi Town Planning, the Consultant
must take into account the safety impacts of the size and material used in the NDRC works, if they
are available at this stage.

3.5.2 Preliminary Design Stage

During this phase, the designer must take into account:
 The specification of materials
 The location of the crossing – to minimise the safety impact on pedestrians, motorists and
the general public
 The diameter – to minimise the impact of construction works for construction personnel
 The ground conditions – to establish the risks of stability of the surrounding soils.

PAGE 19

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

3.5.3 Pre-Construction Stage

This is an important phase for safety considerations as it maps out the construction processes and
methods via the Method Statement. The appointed Contractor should submit:
 A Method Statement which should detail all the construction methods and programme
 A Risk Assessment highlighting ALL risks to safety, rating each in terms of probability and
severity
 A Site Emergency Plan to show evacuation procedures in an emergency
 A Traffic Management Plan to set out the specific requirements for the site.

3.5.4 During Construction Stage

During this stage there are many considerations for the Contractor to consider.
A daily checklist for inspection of the works is included in the Appendix and this is to be checked
back and corroborated with the Method Statement.
The worker should take the following general precautions:
 Do not take chances that may lead to injury
 Either use tight sheet shoring to guard against the caving in of sandy soil or loose material
when the depth of the excavation exceeds 1.5 meter, or cut back the bank to the proper
slope. Keep shoring at or near the bottom of the ditch as it is excavated and follow with
bracing to ensure safety. Trench shields are also acceptable as a protective system. A
trench shield does not protect the environment, only the worker.
 The placement of shores will depend on the type (classification) of soil encountered. Local,
state or provincial, and federal laws man - date the distances and sizing of shoring support
systems.
 Extend shoring of any type below the excavation bottom whenever possible, and brace it
thoroughly using timbers, wedges, and cleats, or a pipe/screw-jack combination. Place all
bracing at right angles to the sheeting or uprights and rigidly wedge, bolt, or cleat it to
prevent movement. Hydraulic units are being used in many types of utility-trench
construction
 Use only full-sized lumber that is assessed to be sound and straight.
 Install the upper braces or screw jacks first, and remove them last for best protection.
 Also consider excavation dimensions, soil stability, variable weather and moisture
conditions, proximity of other structures, weight and placement of soil and equipment used
on the job, and sources of vibration when choosing the type of shoring to use, if any. The
decision must rest with the engineer or foreman in charge.
 Use hydraulic jacks temporarily only, and replace them with properly sized screw jacks or
solid bracing.
 Personnel should not be required to do heavy lifting that may cause injury; use mechanical
lifting devices to raise, lower, or suspend heavy or bulky material when working in
trenches, manholes, or vaults.
 Use ladders where required. Do not jump into an excavation.
 Provide an adequate means of trench exit, such as a ladder or steps. Locate it so no more
than 7.5m of lateral travel is required. Extend the ladder from the bottom of the excavation
to at least 1 m above the ground surface.
 Do not place excavated material closer than 1.0m from the edge of an excavation.
 Keep all tools, working materials, and loose objects orderly and away from the excavation
shoulder.
 Keep tools, equipment, and excavated material out of open traffic lanes.
 Take work breaks, rests, etc. at designated locations away from the excavation.

PAGE 20

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 When resuming excavation after heavy rains or freezing weather, inspect all banks for
cracks. These may indicate earth movement and the probability of cave-in.
 Daily, inspect the sides and rim of all open excavations to guard against cave-in. Operate
earth-moving equipment from a position that will not imperil personnel or property by a
cave-in due to vibration, stress, or dead weight.
 If it is absolutely necessary to work above an overhanging bank, use a safety belt and a
lifeline. Have a helper nearby to assist in an emergency.
 To avoid striking electric or telephone conduits, gas lines, or other sub-structures, locate
other utility installations before starting work.
 Require workers to wear adequate eye, ear, and foot protection when using a jackhammer
or when exposed to flying particles or falling objects.
 Workers should always be aware of locations of running machines (back–hoes, trenching
machines, etc.). Workers should keep clear of the sweep path and try never to turn their
backs toward the working machine(s).

3.5.4.1 Pipe storage

 Keep pipe yards and walkways clean and orderly.
 Always block pipe to prevent it from rolling or falling.
 Arrange and block each row of stacked pipe to prevent it from rolling from the pile.
 Store small pipe in racks according to length and size.
 Store pipes larger than 2inch diameter by stacking them with spacing strips placed
between each row.
 Withdraw pipe from the top rows.

3.5.4.2 Shoring and bracing

 Use proper shoring and bracing to prevent cave-ins while vaults or similar openings are
under construction.
 Proper shoring cannot be reduced to a standard formula.
 Each job is an individual problem and must be considered under its own conditions.

3.5.4.3 Posting barricades and warning signs

 Place advance warning, instructional signs, barricades, and delineators well ahead of the
construction area to warn motorists and pedestrians of the area and safely take them
through or past it.
 Protect the work area with barricades, barriers, or planks to provide a safe working space.
If necessary, use flaggers to direct and slow down traffic. When used, place trucks or air
compressors between the work and the traffic.
 During periods of reduced visibility, use adequate lighting on all barricades.
 When no work is in progress, place adequate barriers, barricades, flashing lights, and signs
to warn and divert traffic. Use reflecting tape on all barricades.
 All personnel should wear protective clothing including hard hats and high visibility traffic
vests.

3.5.4.4 Trenching machines

The following rules apply equally to all mechanical devices used to dig trenches and/or make
excavations including various types of trenchers, buckets, scoops, and similar pieces of
equipment:
 Operators should always wear hard hats.

PAGE 21

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

NDRC MANUAL

 Never attempt to oil or grease a mechanism or repair or adjust any moving part of a
trenching machine while it is in operation. Only qualified personnel should operate a
trenching machine.
 Guard all moving parts. Before starting the conveyor, make sure that no person is
endangered by it.
 To remove obstructions from the conveyor mechanism or buckets, stop the machines.
 Be alert for falling material that might roll from the conveyor.
 When practicable, drop dirt between the excavation and the high-way to act as a barrier.
 Cautiously fill gasoline or diesel tanks. Keep spout in metallic contact with the machine to
prevent static sparks from bridging the gap and igniting the vapours. Do not smoke. Keep
proper fire extinguishers available when refuelling construction equipment. Use only
approved containers when storing flammables on the job site; clearly mark and define
storage areas.
 Use flags by day and flashing lights or flares by night to warn the public of the trenching
machine and its operations. Liberally use these precautions on all highway or street work.
Plan the warning system before the work is started.
 Operate the machine vertically to prevent undercutting the trench wells.
 When loading or unloading trenching machines or other heavy equipment from truck beds,
lowboys, or other conveyances, provide suitable skids and ample blocking to prevent
movement of the conveyance
 When manually lifting or lowering pipe in an excavation, use two or more rope slings
looped under the pipe and handle from each side of the excavation. To prevent a heavy
pipe from pulling workers into the excavation, anchor one end of each rope sling to a
massive object such as a truck.
 When aligning pipes in the excavation, either manually or mechanically, keep hands and
fingers away from ends of pipe and other substructures that could crush.
 Govern crane operations only by the signals of a qualified worker.
 Never try to catch and hold a length of pipe that slips from a crane or hoist sling.
 Be alert to unsafe excavation sides when measuring, testing, or inspecting pipe in place on
an excavation bottom.
 When cutting sections of pipe, keep feet in the clear and use adequate blocking, chocks,
etc. to prevent pipe movement.
 Wear safety goggles
 Keep tools and appliances in good condition for handling, cutting, threading, or treating
pipe. Always use the right tool for the job.
 Do not let tools or materials become stumbling hazards where pipe is being handled.
 Avoid shortcuts and makeshift methods that may increase the hazards of handling pipe.

PAGE 22

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Accidents and risks that may be particularly related to NDRC work will include, but are not
limited to:
 Falling accidents (deep excavations and shafts)
 Materials falling from a height
 Collapse of excavation or shaft
 Road collapse or failure
 Flooding from broken pipelines or groundwater
 Striking other utilities (power, gas, oil, water, etc.)
 Suffocation due to inadequate fresh air supply (manned pipe jacking or micro-tunnelling)
 Dangerous gasses
 Rotating and moving machinery and equipment
These along with any other risks must be assessed in the Health and Safety plan including
mitigation measures.
Employment of workers inside pipe jacking or micro tunnelling pipelines shall not be permitted for
pipelines with an internal diameter smaller than 1.2 m.
The Contractor shall develop an emergency plan that describes actions to be taken in the event of
any sudden surface settlement or collapse. This plan shall be included in the Contractors method
statement.

3.6 Environmental requirements

General environmental requirements for any construction works in connection with main roads,
including undertaking of NDRCs, can be found in the DOT-M-08 EHS Manual for Road Projects.
Prior to commencing any projects an environmental permit must be acquired from The
Environment Agency - Abu Dhabi (EAD). Points that will need to be addressed for the
environmental permit may include:
 Soil or spoil removal including slurry handling and disposal.
 Dewatering including discharge.
 Waste management.
 Handling and storage of any hazardous materials.
 Activities creating dust, air pollutants or odours.
 Noise or vibrations.
 The Contractor is responsible for establishing, operation and decommissioning of the work
site in an environmentally safe way and this can be controlled by using a daily checklist
report which will be followed in line with the Method Statement. Such details will be
included in the Contractor's Method Statement.
 All waste materials shall be collected and disposed of in an appropriate manner, and the
site shall be cleared and void of any waste matter after the construction is completed.

PAGE 23

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 All materials and equipment shall be stored in accordance with manufacturer's guidelines
and in a way so that spills or emissions are avoided.
 Drilling fluids (slurry, bentonite, etc.) shall be recovered for reuse or disposal at an
approved location in accordance with the environmental permit.
 The environmental issues that typically concern HDD include:
- Access restrictions due to wetlands, streams, endangered plant or animal life,
endangered habitat, and potential erosion
- Oil and fuel spills from construction equipment
- Drilling-fluid surface spills that endanger animal and plant life
- Drilling fluid returns in water bodies
- Groundwater contamination from drilling-fluid additives
- Drilling-fluid disposal locations (The contractor must obtain approval to disposeof
the drilling fluid at an approved disposal location. Bentonite is a good product for
sealing drainage ditches, irrigation reservoirs, and livestock ponds.
However, approval must be obtained from EAD permit received for the works.

3.7 Site condition survey

A site condition survey shall be conducted during both the preliminary design and construction
stages of the proposed NDRC. All surface and subsurface construction within a minimum of 30 m
from the proposed centreline and any shafts must be identified and the exact location determined.
These will include, but are not necessarily limited to:
 Cables, pipelines, sewers and manholes
 Pavements, footpaths, etc.
 Buildings
 Foundations, retaining walls, etc.
 Artificial cavities
 Constructional systems that have remained in the area along with any other structures or
systems that may have impact or be influenced by the intended NDRC.
A building and structure assessment plan documenting the condition and including photographs of
any existing damage must be included in the site condition survey. This shall be submitted for
approval of both the preliminary design and final design. In connection with the final design the site
survey must be reviewed and approved by the DMAT road maintenance consultant and approved
by the DMAT.
Immediately prior to construction the site survey shall reviewed by the Contractor and any
changes in the condition of buildings, structures, roads, footpaths and other paved areas shall be
recorded and photographed.

3.8 Geotechnical Investigation

The geotechnical investigation shall be conducted in accordance with the Manual for Geotechnical
Investigation and Geotechnical Design including determining the projects geotechnical category
and the procedures for managing geotechnical risk as described.
Evaluation of soil conditions on NDRC projects is critical, but often under-emphasized. Success or
failure is intricately tied to correctly matching equipment and methods to soil Conditions. It is the
designer's responsibility to ensure that sufficient geotechnical information is available for the
complete design and safe installation of the NDRC.
For all NDRC work, a minimum requirement of a desk study shall be carried out, assessing the
available literature, maps, aerial photographs, utility plans and existing site investigations. The
aerial photographs must encompass as much historical information as possible, that show for

PAGE 24

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

example lowlands swamps which have since been backfilled. Existing geotechnical investigations
may be acquired from the road department, adjacent building owners or structures and other
utilities agencies.
If insufficient geotechnical information is available for the area where an NDRC is proposed, then
a thorough geotechnical investigation must be conducted.
The soil investigation analysis is necessary for:
 Selecting the appropriate NDRC method, jacking technique and jacking works
 Selecting and designing the sup
 ports for launch and reception shafts
 Selecting and designing jacking pipes
 Planning measures for soil improvement in unstable soils
 Planning of soil disposal (landfill, treatment, recycling)
 Planning of measures for the control of groundwater
The field exploratory techniques selected should be appropriate to the type of ground and the
planned depth of the NDRC. The laboratory testing programme should include tests relevant to the
ground conditions and the NDRC techniques likely to be employed.
Below suggests parameters to be considered in relation to each soil type.
The soil conditions shall be investigated and documented in accordance with the AD-D-
02Geotechnical Investigation and Geotechnical Design (Vol. 1 & 2). The investigation should
result in information on reliable soil parameters which are necessary for the adequate design of
the drives, shoring, and dewatering details (see Table 1). Analysis and design (calculations for
jacking forces, stress analysis on the pipeline, ground surface settlement and heave analysis, etc.)
should be based on such parameters.

3.8.1 Minimum requirements of the exploratory boreholes

3.8.1.1 Number of boreholes:

 2 exploratory holes for crossings less than 25 m
(one at each end)
 exploratory holes for crossings greater than 25 m
(each end and centre)
 Additional holes for long crossings or in areas with
difficult soil conditions (layered)

3.8.1.2 Depth of boreholes:

 Down to 2 m below pipe invert in groundwater free
soils
 Down to 3 m below pipe invert in groundwater bearing soils
 Down to the planned bottom edge of sheeting in the area of launch and reception shafts.

3.8.1.3 Borehole Positions

Exploratory borehole positions should be chosen to provide
information on the nature of the ground that will be
encountered by the NDRC. Under no circumstances should
boreholes be sunk on the line of the NDRC. .All boreholes
should be properly backfilled and sealed. Piezometers
should be installed where recommended. Boreholes should
always extend sufficiently far below the invert level to

PAGE 25

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

identify changes in the strata below the NDRC that could affect both the construction and long
term impact of the NDRC. Boreholes should be sunk adjacent to shaft locations. Additional
boreholes should be considered, if required, to identify the location of significant changes in
geology or to resolve other geotechnical uncertainties.
All geotechnical investigations shall be carried out by qualified personnel and in accordance with
The TR-535 and TR-536 “Geotechnical Investigation and Geotechnical Design” (Vol. 1& 2).

Table 1: Required Soil Parameters

Non-
Cohesive Mixed Fill
Test Cohesive
Soils Soils Material
Rock
Soils
Unit weight and moisture
X X X X X
content
Angle of friction X X X
Particle size distribution X X X X
Abrasivity X X X X X
Cohesion X X X
Types and proportions of
X X X X X
minerals
Standard penetration tests X X X X
Permeability and nature of
ground water level and flows X X X X
(seasonal/tidal changes)
Toxic/hazardous constituents
X X X X X
in the ground/groundwater
Frequency and physical
properties of boulders, X X X X X
cobbles or flints
Pump down tests X X X X
Presence of gases X
Compressive strength X
Rock quality designation
X
(RQD)
Core logging (TCR, SCR, FI) X
Tensile strength X
Specific energy
X
(excavatability)
Slake durability X
Geological description X X X X
Plasticity indices (LL, PL, PI) X X

(Source: Reference no.3)

PAGE 26

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

3.8.2 Geotechnical Ground Model

A geotechnical section along the drive path shall be provided with the true ground surface elevations and
ground water levels as well as with the elevations of the strata top and bottom lines. The elevation of the
proposed drive shall be plotted on this section as well to show the type of strata above and below the drive.

PAGE 27

03-GENERAL REQUIREMENTS FOR NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

4. PROCEDURES FOR UNDERTAKING NON-

DISRUPTIVE ROAD CROSSINGS (NDRC)
4.1 Overview
This chapter contains the general procedures and requirements for undertaking any NDRC works
under DMAT roads. It is divided into sections relating to the process map described in Chapter 1.

4.2 Concept Stage

At this early stage, the concept of each project will be considered by the Designer, and as per the
stage gateway process, the options will be considered from a financial and environmental impact
point of view before progressing to the next stage. This will be in line with the requirements of
Town Planning as detailed in Chapter 3.
For NDRC, if applicable the impacts will be established and examined, and put forward into the
report generated by the Consultant. Depending on the project, it may be the case that different
routes for the NDRC are considered.

4.3 Preliminary Design Procedures

4.3.1 Method selection
In this section more detailed information about the guidelines requirements and criteria related to
the two major NDRC methods are currently used in emirate of Abu Dhabi are given in order to help
select a method appropriate for the given project. More information on the various methods can be
found in Chapter 3.
The Client/Consultant should, before tender, determine which methods may or may not be used for
the NDRC works. The selection should be appropriate for the intended installation and meet the
requirements of this Manual. Method and equipment should be selected to avoid ground loss and
minimize settlement or heave. Also, a geotechnical section along the drive path shall be provided
with the ground surface and groundwater elevations shown. This will assist in determining the
method.
The selection of route and method shall be based on the information gathered during the site
investigation and geotechnical survey along with all other relevant information. The line and level
of the route shall be selected so as to avoid driving through weak/strong soil boundaries,
weathering interfaces and groundwater surfaces.
The methods presently available are many and diverse and new techniques are continually being
developed. Existing methods and equipment are becoming more advanced and variations or
combinations of different methods are also being developed.
The selection of method is also dependant on the:
Cost – The cost of construction can vary dramatically depending on the method, materials, and
route chosen.

Traffic Impacts – Designers and Contractors need to consider the negative effects on short term
traffic flow impacts

PAGE 28

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Depth – The depth of the crossing as a wider effect on the extent of trenching required and safety
of personnel.
Risk to surrounding utilities – Alternative methods should be considered when there is a large
impact on any surrounding apparatus. Risks should be assessed.

Groundwater impact – The level of ground water can affect the ability to construct in a safe and
efficient manner.

Required installation speed – Due to construction constraints it may be required to carry out a
fast installation. If so, the most appropriate method should be chosen.

Settlement risks – Depending on the soil type encountered, the risk of settlement of the soil may
be high – this should be taken into consideration.

Pipe size – The size of the pipe crossing effects the depth and type of construction chosen.

Length of crossing – The length of the pipe is a strong deciding factor in the type of construction
to adopt.

Required accuracy – All crossings must follow the route decided, however in some cases it may
be that a method is chosen where the required accuracy is not as high as others.

Feasibility of Open Cut – It may be the case that an open-cut dig is found more appropriate. This
will be decided early on in the process.

The selection of the suitable method is also dependant on the type and size of Cable or Pipe to be
laid along with length of the crossing. The range of applicability of available NDRC methods vary
according to the size and the length of the drive as well as to the alignment expected accuracy.

PAGE 29

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Table 2 provides detailed NDRC methods depending on the different soil types.

Table 2: NDRC Methods related to soil types

Parameter Impact Pipe Guided HDD Guided Pilot Pipe

Molling Ramming Systems Mini HDD Systems
Systems
Midi
Hard rock X X X X X
Soft rock X X ◙ X X
Hard clay X X ◙ X X
Soft soils     
Sand & gravel X ◙ ◙ X X
Sand     
Cobbles/boulders X X X X X
Obstructions X X X X X
Below water table  X   ◙
Parameter Auger Boring Directional Tunnelling Pipe Micro- Mircrotunnelling
Drilling Jacking tunnelling Slurry & EPB
Auger
Hard rock X  ◙ X ◙
Soft rock ◙  ◙ X 
Hard clay     
Soft soils ◙  ◙ ◙ 
Sand & gravel X ◙ ◙ X 
Sand ◙  ◙  
Cobbles/boulders ◙ ◙ ◙ X ◙
Obstructions  ◙ ◙ X ◙
Below water table   X X 

X – Not Suitable – Suitable ◙– May be Suitable (depends on specific circumstances)

PAGE 30

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Table 3 shows different applications for NDRC works and the options for alternative construction
methods.

Table 3: Different applications of NDRC

Micro-
Auger Directional Tunnelling Micro-Tunnelling
Utilization Tunnelling
Boring Drilling Pipe Jacking Slurry & EPB
Auger
Cables U ø U U U
Flexible
Conduits
U ø U U U

Gas lines U ø U U U
Oil lines U ø U U U
Potable
water
U ø U U U

Force mains U ø U U U
Gravity
U S O O O
mains
Gravity
U S O O O
Sewers
O – Suitable at appropriate diameters and lengths ø–Suitable for small diameter only
U – Typically for Under Crossings only S – Siphon crossings only

Micro tunnelling and Horizontal Directional are the most used methods in Emirate of Abu Dhabi, so
more discussion will be explained.

4.3.1.1 Micro tunnelling Method

All types of Micro tunnelling boring machines have the following functions in common.
Mechanized ground excavation and stabilization of the face
The head of the machine is equipped with a cutting wheel whose tools are used to last the soil
under the combined action of rotation and thrust. A crushing cone located behind the cutting wheel
and intended to reduce the size of larger elements to allow their mucking, is present on most
machines. There exist different cutting heads for various types of soil(see Figure 19). They can be
distinguished by their cutting tools.
For sandy or gravely soil, the cutting wheels are equipped with teeth (Figure 19). In rugged soil,
these teeth dislodge the blocks, which are then crushed.

PAGE 31

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Figure 19: The different cutting heads (JUN Engineering Co., Ltd.)

For coherent soil (silt, clay, marl) the cutting wheels are fitted with tools which cut out chips of soils
(see Figure 19).on some machines, high pressure water jets are sprayed on the wheels and in the
slope to prevent sticking of clay and clogging of the mucking system.
Finally for rocks (see Figure19) the cutting heads are equipped with rotary cutters having small
openings with the help of the thrust, the rotary cutters crush the rocks by means of shear and
tensile stresses, which create cracks and loosen the fragments, these machines can bore through
the rocky soil with a compression strength of 200 MPA.this type of cutting wheel, also used in soil
contains large rocks, is not suitable for clayey soil.
To ensure the stability of the face, the contact pressure of the cutting wheel and the confining
pressure must be equal to the earth pressure and to the pore pressure of water if the boring is
done under the ground water table.

Disposal of rubble (mucking)

There are three types:
Hydraulic mucking – Removing the earth in suspension in a freely flowing fluid to the outside.
That fluid can be water or pressurised bentonite slurry(see Figure 20).
 Mucking with a screw conveyor – The rubble is extracted from the slope using a spiral
conveyor (see Figure 20).
 Pneumatic mucking – This is a system that is rarely used and consist of mucking by
suction where the rubble is extracted from the face into an airtight vacuum container.

PAGE 32

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Figure 20: Principles of a hydraulic mucking boring machine (Herrenknecht AG)

Monitoring and correction of trajectory

Controlling the actual trajectory of the boring machine in relation to its theoretical position ,is done
using a laser beam with the sensor located in the start shaft whose impact on a target placed in the
machine helps visualize the deviations in trajectory with the help of a camera on board the boring
machine.
When the deviation s become excessive it is possible to correct the direction of the machine whose
head is articulated by moving the three cylinders placed 120 c apart.
4-installation of pipelines by jacking.
This is done by successive jacking of pipes behind the boring machine, this pipe jacking is ensured
by a thrust frame equipped with hydraulic cylinders and located in the starting shaft.

Pipes Materials

 Many types of materials are used:-

 Concrete pipes represent the majority of pipelines that are currently laid.
 Pipes made of composite materials, known as “glass fibre reinforced plastic” offer very
good resistance to corrosion and thus are efficient in transporting corrosive fluids or for
carrying chemically aggressive soil, moreover they offer a high resistance at a lower weight
the external diameters available are between 400 and 2400 mm.

 Steel pipes have the major advantage of offering strong resistance but they are sensitive to
corrosion.

PAGE 33

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 Clay pipes available in diameters of 150 to 1200 mm offer greater resistance than the
concrete pipes at the same thickness when their surface is vitrified, it is extremely resistant
to water absorption and chemical attacks.
 In terms of corrosion resistance the jacking pipes and their joints can be subject to internal
corrosion caused by the transported substances or to external corrosion caused by the
surrounding soil or ground water.
 If the materials used are insufficiently resistant, measures of corrosion protection have to
be taken and approved by DMAT.
 For steel and ductile cast iron pipes the internal protection shall not be damaged during the
jacking process.
The methods vary in size, length and accuracy as shown in Table 4. Due to the limitations in
accuracy, non-steerable methods should only be used over short distances. The soil conditions
and groundwater levels are of great importance in determining the most suitable method for a
given NDRC. In Table 2 a number of the common methods are shown with their respective
application in various soil types.

Table 4: NDRC methods with typical pipe size, length and accuracy

External pipe Maximum Accuracy Minimum

diameters, De length ground cover
Non-steerable:
Impact moling/soil Up to 200 mm 25 m 1-2 % of length 10 x De
displacement hammer, Min. 3.0 m
Pipe ramming with closed pipe
Pipe ramming with open pipe, Up to 2000 mm 80 m 1-2 % of length 3.0 x De
Auger boring Min. 3.0 m
Steerable:
Horizontal Directional Drilling 40 - 1200 mm 1800 m 2-5 % of depth
(HDD)
Micro tunnelling 400-4500 mm 1000 m +/- 20 mm 3.0 x De
Min. 3,0 m
Pilot pipe with auger spoil 100 - 1200 mm 100 m +/- 20 mm 3.0 x De
removal Min. 3.0 m
Manned steerable:
Pipe jacking 1500 - 4500 1000 m +/- 20 mm 3.0 x De
mm Min. 3.0 m
Hand excavation:
Hand dig + Mechanical Min 1500mm 125m Varies 3.0 x De
excavator Min. 3.0 m
(Source: Standard DWA-A 125E, Pipe Jacking and related techniques)

Micro tunnelling or pipe jacking with closed front can also be applied in nearly any soil condition
with the suitable bore heads and spoil removal systems. However, in very loose non-cohesive
soils, with high groundwater levels, there is a risk of removing excessive soil in front of the bore
head, which may lead to immediate or future surface settlement.
In very loose soils or areas where soil investigations have indicated subsurface cavities, a decision
must be made either to construct deeper in an attempt to find suitable soil conditions or to apply
ground treatment methods prior to undertaking the NDRC.

PAGE 34

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

The final selection of an NDRC system should be developed using available factual and reliable
soil data and surrounding constraints. The system should include the recommended route (line and
level), boring size, NDRC method, pipeline details, equipment, and operational variables, all of
which, in combination, will achieve the required tolerances. The proposed system should then be
analyzed for:
 Jacking/pulling forces.
 Lubricant characteristics.
 Face stability.
 Thrust reaction elements.
 Structural design of pipe and joints.
 Ground surface movement (both short and long term settlement and heave).
Please refer to the Tunnelling and Pipe Jacking Guidance for Designers table which is shown in
Appendix E.
Drilling fluids
Functions
Generally, the fluids used for boring may have several essential functions:
 maintaining the cutting in suspension and ensuring its removal by hydraulic channels: this
obviously is a function that is directly applicable to boring machines with hydraulic mucking;
 guaranteeing the stability of the bore, strengthening the walls and preventing loss of fluids
by creating an external or internal “cake” that is as fine and as resistantas possible. This is
a supporting function;
 lubricating and cooling the tools, drilling strings, on-board equipment and pipelines;
 facilitating digging by jetting. This function is sometimes necessary in clayey ground

The drilling mud is essentially made up of a stable colloidal suspension in a Dispersing agent like
water. Two families of colloids are mainly used:
 Mineral: mainly bentonite,
 Organic: mainly water-soluble polymers.

This suspension is rapidly altered by solids in the ground and possibly by water contained in the
ground to be crossed and the minerals contained in it.
The bentonite are industrial clay of the smectite group. They are characterized by a foliated
structure, which is negatively charged on surfaces and positively on.

Main characteristics
Main characteristics parameters of drilling fluid, which determine its behavior and which must be
regularly measured and recorded as the digging work progresses:
 the density, which is an index of the content of solid element in the polluted sludge; it must
generally be between 1.0 and 1.2;
 the viscosity, which characterizes the ability of forming a cake as well as the ease in
transportation of the mucking; measured at the Marsh cone, it must generally be between
32 and 40 seconds in clayey ground, and greater than 50seconds in sandy ground;
 the yield point, the thixotropy and the filtrate that determine the formation of the cake and
its ability to reform rather rapidly; in a filtration test, clean sludge must present a cake less
than 4 mm and a filtrate less than 40 cm3; in polluted sludge the cake must remain less
than 3 mm, and the filtrate must be in the region of 6 cm3 in clayey ground, and 10 to 15
cm3 in sandy ground;

PAGE 35

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 the sand content, which results from the separation result of solid earth and which affects
the permeability of the cake and therefore its stability; it must generally remain less than 4
to 5 % (measured with the elutriator);Guidelines for a Project Design 297
 the pH, which affects the ionic balance and thus the physico-chemical properties of the
sludge; it must remain within a range of 8 to 10;
 the conductivity and the hardness are also indices that may be useful.

NOTE: the values indicated above are only to indicate the order of magnitude generally used in
trenchless work. They must however be adjusted according to predominant performances, which
are dependent on the ground.
Implementation of drilling fluids requires suitable manufacturing, storage and solid treatment
equipment:
 mixers,
 main and auxiliary pumps,
 mud tanks, vibrating screens, hydro cyclones, centrifuges, and possibly a plant for the
physico-chemical treatment of waste.

The equipment as well as the quality of process water and the temperature will significantly affect
the performances of the sludge.
On the other hand, it is very essential to emphasis that the storage conditions (long periods, humid
atmosphere, etc.) can significantly alter the characteristics of the bentonite powder.
Fractures. Upon contact with water, the flakes disperse, swell and possibly exchange the charge
compensating actions.
Beyond a certain concentration (relatively low) of the order of 4 to 6%, and depending on the
quality of bentonite, a stable structure develops and has certain Rigidity under shearing.
The bentonite can be combined with additives for various functions:
Viscosifying, fluid-loss additive, water reducer, clay encapsulator and stabilizer, Lubricant.
The most common are water-soluble polymers which, in addition to their ability in increasing the
viscosity, present special physico-chemical properties.
There exist several types that are natural, artificial or synthetic, which can remedy specific
problems relating to certain soil materials, such as:
- Sticky or swelling clay,
- Improvement in the stability in sand and gravel,
- Better resistance to physical or chemical contaminations,
- Abrasiveness.

4.3.1.2 HDD process

All types of horizontal drilling have the following common functions:

Drilling of a pilot tube

A drill string is inserted into the ground applying on the bottom hole assembly acombined thrust
and rotation action. This bottom hole assembly has a special featureof being asymmetrical in
relation to the longitudinal axis. Mere thrust forces it todeviate, but rotation combined with the
thrust gives it a straight trajectory.

PAGE 36

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

This bottom hole assembly consists of an electronic tracking device and more orless sophisticated
cutting tools. These tools are either simple drill blades or drill bitsdriven by hydraulic or pneumatic
motors.
Monitoring and correcting the trajectory
The installation of pipelines by horizontal drilling must be able to:
 Constantly locate the position of the drilling head in the ground so as to respect the
specified trajectory and avoid the already existing utilities: this is the tracking function;

 Know the pitch of this head and its direction to guide and divert its trajectory
:this is the guidance function.
 It is in fact the asymmetry of the head (wearing blade and nozzles in the case of a
conventional head or a bend in the case of a mud motor) which by stopping the rotations of
the rods diverts the trajectory, thereby correcting it.
 The success of pilot drilling depends on the locating system, its accuracy and ease of use.

Two types of locating systems may be distinguished:

1. Walk-over systems
 These systems are suitable at most sites.
 This technique is easy to implement, is safe for data transmission cables and hasa low
investment cost.
 The walk-over systems have disadvantages such as the reduction in accuracy of
measurements increasing with the drilling depth, the influence of underground magnetic
field interference and an operating range dependent on the life of the transmitter’s
batteries.

2. Down hole systems or wire line steering systems

The systems consist of three elements:
 a transmission probe powered by batteries placed in the drilling head,
 a receiver that helps vertically locate the head and its direction,
 Display of parameters (remote) on the drill rig.

Figure 21: Locating systems (Grundodrill co.)

PAGE 37

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Reaming of the drilled borehole

 Once the pilot hole has been made, the drill string comes out of the exit pit (most frequent
case).
 Generally, the drill string is towed behind the reamer. The hole is enlarged by successive
stages of reaming of increasing sections until the desired section is reached (generally
double the section required by the pipeline).
 This reamer is equipped with injection jets for drilling “mud”. This mud washes out and
disposes of the cuttings created by the reamer, lubricates and cools.
 After the final reaming phase one end of the pipeline built earlier will be tied to the pulling
head fastened to a suitable reamer. It will be pulled from one drilling end to the drill rig.
Installation of pipes or cables
 Used to cross obstacles such as streams or rivers, this guidance technique using data
transmission cables has opposite advantages and disadvantages to the previous system
with a more complex usage technique but with greater accuracy and range.
The horizontal directional drilling system
The horizontal directional drilling system include:-
 Drill unit.
 Guidance system.
 Drilling fluid system.
 Drill pipe and down hole tools, including bits and back reamers.
 Drilling fluid mixing or recycling system.

Figure 22: Basic components of rig (Grundodrill co.)

HDD systems are defined by:

 Thrust and pullback force, stated in pounds
 Spindle torque, stated in foot pounds
 Maximum volume of drilling fluid a machine can pump per minute, and spindleRevolutions
per minute.

PAGE 38

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Table 5: Rigs types and specification

Source: Ref no 1
The composition of drilling fluid and correct/constant pressure are keys in successful installation of
HDDs.
Too low pressure may cause collapse of the bore cavity or clogging of soil removal. Too high
pressure may result in blow out, where drilling fluid is pressed through overlying soils to the
surface.
Horizontal directional drilling can be undertaken in both soil and rock, and there are no specific
limitations underground water. Some restrictions may apply in very loose coarse sand or gravel.
These soils will have a tendency to collapse in the borehole giving either excessive spoil removal
or stopping the pipeline.
Pipe materials are most often plastic (PE, PP or PVC), but steel and cast iron pipes are also
manufactured for use in HDD installations. Pipe materials must be joined and have the strength
necessary to withstand the pulling forces applied during installation.
The accuracy of HDD is dependent on the accuracy of which the drill heads location and depth can
be determined during drilling. Accuracy has typically been set at 2-5% of the depth, but more
accurate transmitting/receiving equipment is continually being developed.

Drill Bits
The latest bit designs are for specific types of soils, including rock, cobble, and other difficult
conditions. Carbide makes today’s bits more productive and last longer.
Bits are designed to run smoother in difficult conditions, with less vibrationtr
an smitted to the drill unit.
A truly universal bit that is effective in all soils has yetto be developed, but some of the latest bits
can be productive in a much wider rangeof soils.
For much of today’s short- to medium-range utility applications, slant-facebits also make it possible
to change the direction of the path of the pilot bore.

PAGE 39

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Many new bit products are for rock work, and drilling and steering through hard rock remaina
challenge for both tool and drill-rig designers.
Some drill bits are used for steering and to excavate the soil or rock at the faceof the bore.
The types of drill bits commonly used in HDD applications are traditionalSlanted-face bits, slanted-
face rock bits, and hard rock or mud motor bits.
Table 6 provides some application guidelines for the various types of drill bits.

Table 6: Drill Bit Types and Application Guidelines (Courtesy DCCA)

PAGE 40

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

NDRC MANUAL

Figure 23: Slanted face Drill Bits (Ref.1)

Figure 24: Modified Slanted face Drill Bits (Ref.1)

PAGE 41

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

NDRC MANUAL

Figure 25: Modified Slantedface Drill Bits

Figure 26: Rock Drill Bits (Ref.

PAGE 42

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Figure 27: Tri-Cone Rock Bits

Operational risks in HDD installations:

Many risks will be associated with the HDD operations.
Lists those risks must be assessed within any method of statement will be submitted to DMAT to
get approval for HDD operation.

PAGE 43

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Table 7: Operational risks in HDD installations (Baumert and Allouche 2003)

4.3.1.3 Working shafts, entry and exit points

Launch and reception shafts shall be designed and constructed to withstand all applicable static
and dynamic loads including the maximum driving force that may be applied. The location of
launch and reception shafts shall be selected to ensure safe working distances to roads, buildings
and other structures (see Figure 28).

PAGE 44

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

NDRC MANUAL

Figure 28: Working shafts

Table 8: Design of working shafts in Dry ground(Source: Reference- 3)

PAGE 45

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Table 9: Design of working shafts in wet ground (Source: Reference - 3)

For DMAT Main Roads, a minimum distance of 5.0 m from any shaft to the edge of the toe
embankment shall be ensured. For Municipality roads in cities or towns, this distance may be
difficult to achieve due to buildings and other structures. If 5.0m cannot be achieved, then
Consultant/Contractor shall present the reasons and the methods proposed to protect the asset
affected by the crossing. Special care must therefore be taken in the placement, excavation and
backfilling of shafts to avoid any damage. Slope stability must be examined and taken into
account when submitting solutions to the DMAT.
For horizontal directional drilling (HDD) the entry and exit points should be at a sufficient distance
to ensure the acceptable radius of the drilling equipment and piping material.

Table 10: Shaft Dimensions

Mini Rigs Midi Rigs Maxi Rigs

Drill Rig Area Required 1.0m x3m-2.1mx6.0m 2.1mx6.0m-2.4mx13.5m 2.4mx13.5m
(Width x Length)

Recommended Work 6mx18m 30mx45m 45mx75m

Area requirements
(Width x Length)

(Source: Reference- 1)

PAGE 46

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

The dimensions of launch and reception shafts shall be kept to a minimum necessary to construct
the NDRC. Examples of shaft sizes for pipe jacking or micro tunnelling are shown in Table 11.

Table 11: Shaft sizes

External Pipe Segment Dimensions of Dimensions of

DN
Diameters (mm) lengths launch shaft reception shaft
2.0 m diameter 2.0 m diameter
200 - 300 Up to 406 1.0 m
or 2.5 m x 2.0 m or 2.0 m x 2.0 m
3.2 m diameter 2.6 m diameter
400 - 800 556 - 970 2.0 m
or 4.5 m x 3.0 m or 3.0 m x 2.5 m
5.8 m x 4.0 m
800 - 1400 1100 - 1720 3.0 m 4.5 m x (2.5-3.0 m)
or 6.0 m diameter
10.0 m x (4.5-6.0 m)
1500 - 3000 1820 - 3600 3,5 m 6.0 m x (3.0-4.6 m)
or 10.0 m diameter

(Source: Reference- 5)

Shafts beneath the water table shall be water tight and the base concrete shall be capable of
withstanding external uplift pressure of groundwater in addition to other loads.
The ground water control is a serious issue in Abu Dhabi and was proven to have been the cause
of a significant number of subsidence and failure cases of both buildings and infrastructural
elements. Local experience with works that require dewatering indicates that it is highly
recommended that the bottom of the driving and receiving pits be fully sealed using either concrete
slabs or injection plugs. Dewatering from outside the pit as well as sump pumping from the interior
of the pit shall be prohibited. The least favourable method which can be applied with low risk
grounds in the rural areas is the internal dewatering from a cut off pit using a shoring system
embedded in a high quality un-fractured weak rock such as mudstones close to stiff or hard clay. If
in such cases the recharge is found to be large or the groundwater took relatively long time to
drawdown a bottom seal shall be used.
Entry and exit seals or ground treatment of the soil outside the shaft will be required to ensure that
there is no soil transport into the shaft when initiating the drive.
When deciding entry and exit points, it is important to allow for a safe soil cover throughout the
crossing length under the road as per Section 4.4.2

4.3.2 Design drawings

Drawings required for approval of the preliminary design include:-
 Map of location
 Plan and profile showing the line, level and diameter
 Plans of existing utilities, buildings and structures
 Geotechnical profile along the drive line (showing ground water elevations)
 Plan of working areas showing approximate size and location of shafts, entry or exit sties

4.3.3 Hand excavation

If hand excavation is considered appropriate (when no other option is available), then this must be
planned very carefully in line with the specific Health and Safety requirements of the project. The
most appropriate tools must be used and all personnel must be adequately trained to work in

PAGE 47

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

confined spaces. Please refer to the Tunnelling and Pipe Jacking Guidance for Designers table
which is shown in Appendix E and consult theDOT-M-08 EHS Manual for further details.

(Source; - The Pipe Jacking Association)

Figure 29: Hand Excavation

4.4 Pre-construction stage

Prior to commencing construction the final design of the proposed NDRC must be completed and
approved by all relevant authorities. This is often undertaken by the specialist Sub-contractor, who
has the experience and the detailed information about the method and equipment to be used.
All calculations, drawings, method statement, etc. must however be approved by the
Client/Consultant before submitting to the Road Authority for construction approval.

4.4.1 Design calculations

Design calculations shall include:-
 Calculations for any thrust and receptions pits/shafts which shall be designed to resist
external soil and water pressure and stresses resulting from the jacking machine.
 Pipe calculations showing capability of pipe to resist jacking and friction forces in the axial
direction along with soil, ground water and traffic loadings in the vertical direction.
 Calculations of friction loads, face loads, interjacks, jacking pressures etc. for the complete
system including thrust walls, which demonstrate how pipes will be installed with no
damage.
 Calculations giving predicted settlements along and adjacent to route of pipeline.
 Calculations supporting maximum jacking capacity with appropriate factor or safety.

4.4.2 Minimum Depth Requirements

For NDRCs with a diameter of 1.0 meter or less, the minimum depth shall be 3.0 meters,
measured from the road surface to the crown of the drive. For NDRCs with a diameter of greater
than 1.0 meter, the minimum depth shall be three times of the NDRC’s diameter.

PAGE 48

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

In other words, where D=diameter of drive and Z=depth to crown of drive, the recommended
criteria are:
• If D≤1.0 meter, Z≥3.0 meters.
• If D>1.0 meter, Z≥3D.

4.4.3 Design drawings

Drawings must include:-
 Comprehensive plan, profile, and section drawings of the proposed drive showing all
necessary details (such as internal and external diameter, wall thickness, joints or
connections)
 Working drawings showing on plan and section the method of supporting excavations
(Temporary Works).
 Drawings showing the location of pits/shafts
including those indicated as permanent
works in the design drawings.
 Foot print plans showing the working site
areas at the thrust and reception pits/shafts,
control room, pipe storage area, craneage
area, slurry tank, generator, etc.
 Plans showing proposed traffic and
pedestrian diversion proposals around all
pits/shafts.
 Details of entry and exit pipe seals and seal
rings in pits/shafts.
 Jacking and receiving pit configurations (plus design and construction details)
 Ground support details
 Any relevant requirements for thrust blocks, backstops etc.
 Site logistics including storage areas, excavation and backfilling procedures etc.
 Plans for de-watering
 Settlement Monitoring Plan, including monitoring points, benchmarks, and survey
procedures.
 Jacking and receiving pit working drawings, including configuration, support, storage details
etc.

4.4.4 Ground Surface Movement

The goal of any NDRC undertaking should be to avoid ground surface movement entirely.
Unacceptable ground surface movement (settlement or heave) shall be defined as movement
greater than 6.0 millimetres vertically anywhere in the centreline of the NDRC drive or adjacent
surfaces and structures. Some important considerations include:
 During pipe jacking, ground movement may occur due to the instability of the face of the
bore, or from the elastic unloading of ground caused by excavation. These may be referred
to as short term settlement and heave.
 Providing good practice is followed, the effect of such movements should not be adverse.
 Long term movements may occur due to closing of the over break.
 Pipe jacking has the advantage that the over break is minimal and may be pressurised in
certain soil conditions.
The combination of NDRC drive methods and pipeline details are the key to preventing excessive
surface movement, which may be related to:
- Diameter and depth of drive.
- Boring method and practice.

PAGE 49

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

- Stiffness of pipe and joint system and structural integrity.

- Joint alignment.
- Maximum jacking/pulling forces.
- Lubrication and flush details.
- Pipe/soil interaction.
- Overcut and its management.
- Face support details.
- Groundwater control details
- Lack of post-installation annular injection
- Over-cutting in layers with consistency differences
- Inadequate rate of advancement
Obstruction collision Regardless of drive method or details, surrounding soil may be susceptible to
excessive movements when disturbed by the drive (bore). The following conditions can influence
ground movements:
- Residual or swell stresses leading to radial-elastic or time-dependent movements.
- Weak soils or shear failure of the face.
- Loose compressible soils around or above the drive leading to densification and
hence ground movement upon disturbance.
- Internal erosion of loose, non-cohesive soil due to uncontrolled groundwater
movements.
- Loss of soil mass due to dissolution of salts by moving water through soils with high
salt content
- Lack of post-installation annular grouting/injection

4.4.4.1 Prediction of ground surface movement

Theoretical procedures, combined with empirical correlations may be used to assess potential
ground movement above the tunnel. Since tolerances against ground surface movements are
small, the Department recommends that worst credible design assumptions and methods be used
in the assessment and that total, not fractional, movements be determined.
For initial assessments, and where ground settlement effects are not critical, traditional settlement
calculations based on an estimated volume loss during tunnelling may be sufficient.
Standard empirical analyses such as those presented by O'Reilly and New should always be
undertaken where the effects of ground settlement due to tunnelling are an issue. Simple methods
of calculating the extent and potential shape of the settlement trough laterally to, and axially along,
the tunnel are given in numerous text books and guidance documents (i.e. CIRIA Project Report
No. 30 1997).
It is generally accepted that ground settlements over tunnels, refer to Fig.1,may reasonably be
presented by an error function of the form (Martos,1958:Peck ,1969)

𝑽𝑨 −𝒙𝟐
𝜹=( ) . 𝒆𝒙𝒑 ( 𝟐 )
𝟐. 𝟓 𝒊 𝟐𝒊
where :- δ: settlement
V: Volume of ground loss
A: sectional area of tunnel,
x: horizontal distance from tunnel centre trough width parameter.

PAGE 50

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

(Source: Reference 13).

Figure 30: Idealized Settlement Trough Over Tunnel

i:Transverse distance to the point of inflection.

Based on Observations on tunnels driven in the United Kingdom, O'Reilly and New (1982)
proposed the following equation for granular soil:-
i= 0.28 Z-0.12
Where
i=width parameter at surface.
Z = vertical distance from surface to centre of tunnel.
The width of the settlement trough is measured by an i value, which is theoretically the horizontal
distance from the location of maximum settlement to the point of inflection of the settlement curve.
The maximum value of the surface settlement is theoretically equal to the volume of surface
settlement divided by 3.0 i.

4.4.4.2 Analysis of subsidence trough

The analysis of subsidence trough consists of several sequential steps:
 Determination of the maximum settlement and dimensions of subsidence trough for
individual excavations
 back calculation of the shape and dimensions of subsidence trough providing it is
calculated at a given depth below the terrain surface.
 determination of the overall shape of subsidence trough for more excavations post-
processing of other variables (horizontal deformation, slope)
 The analysis of maximum settlement and dimensions of subsidence trough can be carried
out using either the theory of volume loss or the classical theories (Peck, Fazekas,
Limanov).

4.4.4.3 Volume loss

The volume loss method is a semi-empirical method based partially on theoretical grounds. The
method introduces, although indirectly, the basic parameters of excavation into the analysis (these

PAGE 51

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

include mechanical parameters of a medium, technological effects of excavation, excavation lining

etc.) using 2 comprehensive parameters (coefficient k for determination of inflection point and a
percentage of volume loss VL). These parameters uniquely define the shape of subsidence trough
and are determined empirically from years of experience.

Figure 31: Settlement expressed in terms volumes.

(Source :- http://www.groundloss.com )

The maximum settlement δ max, and location of inflection point iare provided by the following
expressions:
𝐕𝐨𝐥𝐮𝐦𝐞 𝐥𝐨𝐬𝐬
δ max =
√𝟐𝛑𝐢
Volume loss = Excavation Volume * % of loss
 For typical calculations use volume loss of 10%.
 Moreover, for HDD method the percent of volume loss shall be based on the actual volume
difference/gap between the total pipe/pipes volumes and reamer volume.

Sources of Settlement
Although there are a large number of sources or causes of settlement, they can be conveniently
lumped into two broad categories: those caused by
 Ground water depression:-

May be caused by intentional lowering of the water during construction or by the tunnel
itself (or other construction) acting as a drain. When either of these occurs the effective
stress in the ground increases
 Lost ground.:-

Lost ground has a number of root causes (at least nine) and is usually responsible for the
settlements that make the headlines. By definition, lost ground refers to the act of taking
(or losing) more ground into the tunnelling operation than is represented by the volume of
the tunnel. Thus it is highly reflective of construction means and methods. Modern
machines can be a great help in controlling lost ground but in the end it usually comes
down to quality of workmanship. The causes of lost ground are lumped into three groups:
 Face losses:- results from movement in front of and into the shield. This
includes running, flowing, caving, and/or squeezing behaviour of the ground
itself or simply mining more ground than displaced by the tunnelling machine.
 Shield losses.

PAGE 52

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Shield losses occur between the cutting edge and the tail of the shield. All
shields employ some degree of overcut so that they can be manoeuvred. In
addition, any time a shield is off alignment, the shield yaws, pitches to be
brought back to alignment
 Tail losses.:-Tail losses are similar to shield losses in that they are caused
by the space being vacated by the tail itself as well as the extra space that
must be provided between the tail and the support elements so those
elements can be erected and so that they don't become "iron bound" and
seize the tail shield. However, like the shield losses, these tail voids will rapidly
fill with soil if they are not first eliminated by grouting and/or expansion of the
tunnel support elements

The shape and magnitude of the settlement trough is a function of excavation techniques, tunnel
depth, tunnel diameter, and soil conditions. In the case of parallel adjacent tunnels, surface
settlement is generally assumed to be additive.
For geometrics other than a single tunnel, adjustments of the types given below should be made to
obtain settlement estimates:
For parallel tunnels three or more diameters apart (centre to centre), surface settlements are
usually reasonably well predicted by adding the individual bell curves of the two tunnels. In good
ground and with good practice, this will often give workable approximations up to the point where
the tunnels are two diameters apart.
The ground settlement also can be predicted by numerical methods. The numerical method is
extremely useful when the tunnel geometry is not a circular or horse-shoe shape since
analytical/empirical method is not directly applicable. A sample finite element settlement analysis is
shown in Figure 32.

Figure 32: Example of Finite Element Settlement Analysis for Twin Circular Tunnels under Pile
Foundations (www.nastt.org )

PAGE 53

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Evaluation of Structure Tolerance to Settlement

Where determination of the surface settlement trough is critical, for instance where settlement
sensitive structures are located within the settlement trough, more sophisticated methods of
modelling should be used, such as finite element or finite difference numerical models. In some
cases, 3D numerical modelling techniques may be appropriate. Where numerical modelling is
adopted, use of small-strain stiffness’s can be used if appropriate. However it should be noted that
numerical models using small strain stiffness’s often overestimate the width of the settlement
trough which can lead to an under prediction of the settlement and the associated curvature of the
trough profile.
Settlement analysis, whether using empirical formulae or numerical modelling should consider the
effects of all elements affecting the settlement and settlement profile, which may include, but may
not be limited to:
 Elastic, elastoplastic, and viscoplastic deformational behaviour.
 Immediate, short-term, and long-term movements.
 Consolidation, collapse, and swell.
 Volumetric compression and expansion.
 Volume loss, soil piping, internal erosion, and hydro-compaction.
 Fractional and total ground movements
 Surface conditions including surcharge and topography
 Groundwater conditions, temporary and permanent including the effects of dewatering.
 3D effects
Depending on the requirements of the design, additional monitoring may be required. Such
monitoring may include but may not be limited to the following:
 Vertical and/or horizontal inclinometers
 Vertical and/or horizontal borehole extensometers
 Movement monitoring pins attached to sensitive structures
 Standpipe, pneumatic and/or vibrating wire piezometers
 Strain gauges
 Electrolevels
 Portable seismographs
 Programing of settlement limit triggers.

4.4.4.4 Railways
Special considerations may apply when crossing under or nearby railways. The railway authority
must be consulted for further specifications or requirements. The requirements are not therefore
available because it is under preparation till that time, the following are proposed guidelines from
the international practice used in USA (9).
All utility crossings railroad trackage should have a minimum depth of cover of 1.5 meter below the
flow line of the ditch. or ground surface and 1.65 meter from base of rail. In fill sections, the natural
ground line at the toe of slope will be considered as ditch grade.
For all boring and jacking installations under main and passing tracks, greater than 65 cm
diameter, and at a depth of between 1.65 m and 3.0 m below top of tie, a geotechnical study will
need to be performed to determine the presence of granular material and/or high water table
elevation.
The use of plastic carrier pipe for sewer, water, natural gas and other liquids is acceptable under
specific circumstances. The use of plastic pipe is satisfactory if the pipe is designed to meet all
applicable federal and state codes, and if the carrier pipe is proper lyen cased within a steel
casing pipe. This casing must extend the full width of the right of way. Casing may be omitted only
for gaseous products if the carrier pipe is steel and is placed 3.0 m minimum below the base of rail.

PAGE 54

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

If the minimum depth is not attainable because of existing utilities, water table, ordinances, or
similar reasons, the line shall be rerouted.
Locations that are considered unsuitable or undesirable are to be avoided. These include deep
cuts and wet or rocky terrains or where it will be difficult to obtain minimum depth.
Lines in unsuitable locations and conditions will be tunnelled, augured, jacked or directional-bored
through the roadbed. Refer to the a sections for required encasement of utilities and boring
requirements.
Manholes should be located outside railroad property, when possible. No manhole will be located
in the shoulder, shoulder slope, ditch or back slope, or within 7.50 meter of the centreline of track,
and shall not protrude above the surrounding ground.
Jacking/boring pits shall be located a minimum of 10 meter from the centreline of track, and kept to
the minimum size necessary.
Under-track bores shall be located greater than 45 meter from the nearest, Track switch or other
major structure.

4.4.4.5 Buildings/Sensitive Structures

All NDRC works shall hold a minimum clear distance of 5.0m or 3i to any buildings, foundations,
bridges, retaining walls or other sensitive structures.
No NDRC work shall pass under bridges or retaining walls. If 5.0m cannot be achieved, then
Consultant/Contractor shall present the reasons and the methods proposed to protect the asset
affected by the crossing.
Generally, when dealing with adjacent structures, a full structural assessment must be produced to
establish the potential impact of the crossing.
Precautions that can be adopted to prevent, control or minimise settlement of overlying structures
include;
 Development of accurate baseline conditions.
 A good understanding of the geology to be tunnelled is key to predicting and avoiding or
controlling settlements due to tunnelling. Proper and sufficient site investigation is key to
developing appropriate mitigation methods for controlling or minimising settlements.
 A pre-condition survey of all potentially affected structures should be undertaken prior to
commencement of tunnelling works.
Structural methods such as:
 Underpinning
 Jacking
 Jet Grouting
 Compensation Grouting (during and/or after tunnelling)
 Curtain walling (Sheet piles, diaphragm walls, contiguous bored piles, mini piles)
 Strengthening of affected structures
Ground improvement methods such as:
 Consolidation grouting
 Vibro compaction/replacement of soils before tunnelling
 Ground Freezing
Tunnelling methods such as:
 Use of support fluids during tunnelling
 Use of tunnel shield

PAGE 55

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 Re-alignment of tunnel (horizontal or vertical) to avoid/minimise impacts on sensitive

structures
Planning methods such as:
 Property purchase
 Demolition
 Relocation
 Protection of existing services
 In situ re-lining old/brittle service pipes
 Excavation and replacement
 Underpinning
Contract specifications should clearly state the settlement limits to be adopted for the tunnelling
works and should require contractors to provide detailed method statements describing the method
of tunnelling and precautions and procedures to be adopted to control surface settlements.

4.4.4.6 Remedial actions

Unacceptable ground surface movement or any damage to adjacent structures, as compared to
their reference condition, will necessitate full reinstatement of the affected surfaces or structures in
accordance with the DMAT specifications.
Before undertaking any reinstatement a full report shall be submitted documenting the surface
movement and providing an explanation of its cause. This shall include a geophysical testing of the
affected area in addition to any other tests that may help diagnosing the problem.
A complete method statement of the planned reinstatement must be submitted and approved
before reinstatement work progresses.

4.4.5 Groundwater Control

Due to the risk involved in possible soil displacement, dewatering shall always be kept to an
absolute minimum necessary for satisfactory installation.
Dewatering for NDRC work will generally not be
permitted, however localized dewatering for construction
of shafts or for the launch or reception of the tunnelling
machine may be permitted for a limited time.
Dewatering systems, including an appropriate filter around
riser pipes, should be carefully considered and designed
properly. The dewatering solutions/design shall be
submitted for approval.
The filter design should ensure against the possibility of
any internal soil erosion that might cause ground
settlement and collapse. Filters can be either conventional soil filters or geo-textile filters. The use
of geo-textile filters are preferred and recommended.
Once shafts are constructed these shall be water tight. It is highly recommended that the pits be
fully sealed using either concrete slabs or an injection plug. Any pumping of inflowing water from
the shaft will be considered dewatering.
All water removed from any dewatering system must be disposed of in accordance with the
environmental permit.
A detailed description of the required dewatering along with the estimated amounts of water and
their disposal destination as well as the monitoring system of the water table level during
construction must be submitted for approval along with the Method Statement.

PAGE 56

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

4.4.6 Materials and equipment

Pipe materials shall be selected in accordance with the specifications given by the Client. All
materials shall have the capability of withstanding the pulling or pushing forces exerted during
installation along with the long term loads of soil, groundwater and traffic.
Piping and cable materials shall be chosen to withstand corrosion and other chemical reactions
from both the intended media and groundwater.
All joints and connections must be water tight and be designed to withstand the forces exerted
upon them during installation.
The following information must be supplied for all pipe materials:
 Manufacturer
 Grade/strength
 Outside diameter
 Thickness
 Material composition including any coating
 Connection or joint details
For any drilling fluids or grouts:
 Ingredients, including material safety data sheets
 Design mixes, viscosity, density, etc.
Equipment and machinery:
 Manufacturer
 Manufactured date
 Model or type
 Thrust and/or pulling capacities
 Calibration certificates

4.4.7 Method Statements

The Method Statement shall include all requirements regarding the Contractor's method for
undertaking the works in compliance with relevant designs, specifications, site controls and
restrictions, inspection plans, programme, equipment resources, staff etc.
A complete Method Statement shall be submitted and approved prior to commencement of
construction, including the following in addition to what DMAT would further request:

4.4.7.1 Contractor experience

Documentation detailing the training and relevant experience of the Contractors personnel shall be
submitted which includes all personnel that would be undertaking the work. All personnel are
required to be fully trained in their respective duties and in the safety of operating any equipment
that will be utilised during the course of the works. The following shall be submitted:
Micro tunnelling Qualifications for Contractor Performing Micro tunnelling Work:
 Cover sheet: Date, company name, address, telephone and fax numbers, email
address, and contact person.
 Resumes of managerial, supervisory and operational key personnel:
 Experience in a minimum of3 previous Microtunnelling projects of similar size and
scope.
 Detailed descriptions of their Micro-tunnelling Projects.

PAGE 57

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 Summary sheet of previous projects performed using Microtunnelling that

demonstrates expertise and experience. Named projects may be used more than
once under separate paragraphs if their criteria apply.
 Minimum 3 years of experience performing Microtunnelling of similar size and
scope.
 List 3 separate projects completed using either a Slurry or Earth Pressure Balance
based system.
 Submit for each named project above, and in same order, the following detailed
information:
- Date, full name of project, and location.
- Owner's name, address, telephone and fax numbers, email address, and contact
person
- Client's name, address, telephone and fax numbers, and contact person.
- Employees in charge of work at both head office and site.
- Description of relevant work successfully completed, including ground conditions.
- Features under which pipe passed, depth below the water table, photos, and
published articles if available.
- Additional information as necessary.

4.4.7.2 Working Drawings

Submit specific Working Drawings to include but not limited to:
 Jacking and receiving pit configurations.
 Design and construction of jacking and receiving pits
 Details for ground support system.
 Special requirements for jacking and receiving pit penetrations, thrust blocks, backstops or
other reactions required for Micro-tunnelling, casing pipe jacking or any other jacking.
 Full calculations supporting maximum jacking capacity that jacking pit will withstand without
movement exceeding 1.3 cm with an appropriate factor of safety.
 Areas for storage, material and spoil handling, dewatering, ground stabilization if required,
excavation procedures, and backfilling.
 Dewatering and ground water control plans for all jacking and receiving pits. This includes
the groundwater monitoring system.

4.4.7.3 Construction Works

 The Contractor shall deliver a detailed time schedule for construction sequencing and
programming, clearly showing the planned activities and the work areas involved.
 Supply full details of Microtunnelling System to be employed.
 Manufacturer and date(s) of manufacture.
 Type and model number for whole system if from single source or separate details for each
element of system.
 Confirmation from manufacturer that machine set up is suitable to limit annular space, as
specified, for external diameter of casing pipe proposed.
 System of alignment monitoring and steering control and activation.
 Hydraulic jacking system maximum capacity and method of limiting jacking capacity to that
of maximum capacity of specified casing.
Supply full details of procedures and resources that will be employed to carry out work including
method and sequence of:
 Establishment of drive line of MTBM and elevation at base of shaft.
 Casing Pipe handling and connections.
 Maintaining line and grade, and re-establishment of line and grade as required.

PAGE 58

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 Spoil separation and disposal.

 Spoil and slurry containment during Microtunnelling work.
 Installation of carrier pipe, including placement of grout between carrier pipe and casing
pipe, and procedures to prevent floatation during grouting.
Supply full details of following materials:
 Design mixes for all concrete, grout, or flowable fills. Casing pipe including manufacturer,
grade, and specification, outside diameter, thickness, and any coatings, if required.
Calculations that clearly state:
 Maximum calculated jacking resistance for installing complete casing.
 Maximum allowable face pressure or slurry pressure that can be exerted at tunnel face
without fluid loss to surface, other structures or features or heave of ground.
 Relationship between hydraulic jacking pressure and force applied to casing pipe during
jacking.

4.4.8 Risk Assessment and Risk Register

A risk assessment shall be conducted in accordance with the Risk Management Manual.
The main risks involved in undertaking NDRCs are surface settlement or heave. Other risks that
may be encountered are road user safety that may be derived from surface movement and risk of
damage to existing utilities or structures.
The Contractor must undertake a risk assessment listing all the possible occurrences in a risk
register and evaluated the likelihood and consequences of these occurrences. The risk
assessment shall include analysis and procedures for mitigating risks along with emergency
procedures for dealing with specific incidents.The various methods of NDRC will have different
risks associated with them. A summary of the level of risk associated with each method is shown in
Table 12. This table shall be used as a guide, and the particular conditions of the specific site shall
be taken into consideration.

Table 12: Risk Summary for Typical NDRC Methods

Method Principal risk

Surface Surface heave Road user Damage to existing
settlement safety utilities
Impact moling Negligible High Moderate Moderate
Pipe ramming
(open end) Negligible Moderate Minor Moderate
Auger boring Moderate Negligible Minor Moderate
Horizontal
directional drilling Minor Moderate Negligible Minor
Micro tunnelling Minor Minor Negligible Negligible
Pipe jacking Minor Minor Negligible Negligible

Please see Appendix A for a list of potential H&S risks for NDRC work. In addition to highlighting
the possible risks, the Contractor must also establish contingency plans for correction of potential
conditions. They include:
 Inability to complete the pilot hole
 Excessive fluid loss/hydraulic fracturing
 Inability to pull the pipe

PAGE 59

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

4.4.9 Procedure and logistics for obtaining No Objection Certificates

No Objection Certificates (NOCs) must be obtained from all concerned utilities agencies or
stakeholders that may be affected by the NDRC. A list of the Authorities as a guide but not limited
to those are contained within Appendix A.
Note: Some of the utilities or other authorities may require 2-4 weeks to give NOCs or even longer,
if insufficient information is supplied. The Contractor must make sure that the Town Planning
approval is valid.

4.4.9.1 Conflict with other Utilities

The Contractor/Sub Contractor is required to obtain information on all existing utility lines in the
vicinity of the work area prior to commencing of any excavation. Trial pits shall be excavated to
assure that no utilities are present at the site. Such details are to be included in the approved
Method Statement.
The relevant Authorities should be contacted for approval to dig near their utilities. The most up-
to-date codes and standards are to be adopted.
It is always the Contractor/Sub Contractors' responsibility to ensure that he has obtained all
information on other utilities in the work area and that he has assessed the safe distances to these.
Any damage to any utility during the undertaking of the NDRC is the sole responsibility of the
Contractor/Sub Contractor.
However the Contractor must approach the relevant Authorities for details on the latest standards
for the particular crossing implemented.

4.5 During Construction

The Contractor/Sub Contractor shall keep updated records at the work site for the duration of the
work. A checklist of minimum daily routines for monitoring and record keeping is given in Appendix
D. The records shall be checked and signed by the supervising Consultant.
A Project Board must be generated and installed detailing the specific project details and contact
details of the relevant stakeholders.

4.5.1 Monitoring of Surface Movement

For purposes of monitoring ground surface movement on the roadway, the Contractor shall install
flush-head pins (35.0 millimetres to 50.0 millimetres in length) in the road pavement. These pins
shall be the monitoring points. The pins shall be installed in a grid pattern at approximately 2.0m
centres.
The location of monitoring points and reference benchmarks are to be submitted before
construction. Approval shall be sought from a Road Maintenance Consultant nominated by the
DMAT.
The grid of monitoring points shall cover the entire width of the roadway along the drive and shall
extend outwards in each direction from the centreline of the drive to a distance of the drive
centreline depth below the road surface.
Measurements shall be replicable to an accuracy level of better than 0.5 mm and shall be done on
a daily basis during construction. Displacement measuring instrumentations and method statement
of taking measurements shall be submitted and approved before construction.
Ground surface movements outside the acceptable limit shall be immediately reported to the
Overseeing Organisation and remedial actions be taken.

PAGE 60

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

In some cases where the ground condition is not suitable and/or tunnelling diameter is relatively
large, continuous monitoring of the internal ground settlements along the line path outside the
pavement (between pavement edge and driving pit) must be recorded at the start of the drilling
operation and at regular intervals during the work. Any settlement noticed during the boring
process shall be a sign to stop the work and investigate the reasons before drilling under the
pavement.
Ground surface movement limits in the specified area shall remain in effect for 2 years from date of
completion of the NDRC and shall be monitored on a monthly basis.
The records to be kept by the Contractor and supplied to the Overseeing Organisation should be
established prior to any construction works.
The type of records will vary for each method and project but the following information should be
recorded where applicable, is listed in Table 13.
All surface monitoring shall be referenced back to stable benchmarks located well away from the
influence of the tunnelling works. If no existing permanent stable benchmarks are available within
500m of the tunnel centreline, then a temporary deep benchmark shall be installed.

PAGE 61

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Table 13: Type of record for NDRC projets

Micro Pipe Directional Auger Pipe Impact

Tunnelling Jacking Drilling Boring Ramming Moling

Contract * * * * * *
Reference of pipe run * * * * * *
Date of work * * * * * *
Start time * * * * * *
Finish time * * * * * *
Details of any * * * * * *
stoppages
Diameter of bore * * * * * *
Pipe material * * * * * *
Pipe diameter * * * * * *
Joint packing * * * *
Length installed * * * * * *
Main survey checks * * * * * *
Soil conditions * * *
Ground water level * * *
Line and level achieved * * * * * *

Lubrication * * *
Support Fluid *
Jacking & winch loads, * * *
w.r.t. progress

Slurry pressures, * * *
viscosity, discharge,
flow rate

Shield role, pitching, * * *

steering adjustment
Thrust rate, cutting * * *
torque, soil discharge

4.5.2 Instrumentation Requirements

The following data shall be recorded, if possible automatically, during installation:
For micro tunnelling:
 Line and level
 Maximum jacking forces of the main, and if used, intermediate thrust stations
 Jacking speed/distance
 Quantity of slurry and if possible of excavated soil
 Rolling
 Steering correction

PAGE 62

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

 Maximum interval of recordings should be every 0.2 m of excavation.

The following should be confirmed before and during construction:
 Closed face capable of providing adequate supporting pressure to excavated area
 Use slurry pressure and/or auger earth pressure to achieve the balance of earth and
ground water
 Make sure of the ability to control axial rotation and steer to correct vertical and horizontal
deviation from alignment by remote activation
 Means to inject lubricant over lead pipe, if required
 The spoil transportation system has capacity for removal and balancing of spoil.
 The slurry system operates so that excess fluid can be discharged safely
 Control system enables remote control of all main functions of the system from one location
For manned techniques:
 Line and level
 Maximum jacking forces of the main and if used intermediate thrust stations
 Jacking speed/distance
 Quantity of slurry and if possible of excavated soil
 Rolling
 Maximum interval of recordings should be once per pipe section installed.
For horizontal directional drilling:
 Line, level and length
 Quantity and characteristics of drilling fluid
 Maximum pulling forces
 Maximum interval of recordings should be once per drilling rod.

4.5.3 Equipment Performance Requirements

Closed face capable of providing positive supporting pressure to full excavated area (face) at all
times and capability of controlling and measuring pressure at face.
Achieve balancing of earth and ground water pressures by use of slurry pressure, auger earth
pressure balance or a combination of the two.
System capable of any adjustment required to maintain face stability for anticipated ground
conditions.
Control slurry pressure systems, using slurry spoil transportation, earth and groundwater pressure
at the face by use of variable flow slurry pumps, pressure control valves and minimum of 2 flow
meters, one on feed side and side, and one on return side.
For earth pressure balance systems using a screw auger spoil transportation from the face, control
excavated material by maintaining an earth pressure balancing plug of material at the plug of
material at the face with advance of system being matched with excavation removal through auger.
Control soil through auger by use of pitch spacing and/or an auger gate or throttle.
Sufficient power and ability in normal operation to cut or crush hard material of sizes up to 1/3
internal diameter of pipe and up to 30,000 psi compressive strength.
Ability to control axial rotation to within 3-degrees of normal operating datum.
Ability to articulate and steer to correct vertical and horizontal deviation from alignment datum by
remote activation.
Means to inject lubricant over lead pipe, if required.

PAGE 63

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

Spoil transportation system that has capacity for removal of spoil in balance with excavation and
advance.
Slurry system:
 Spoil separation system sufficient capacity to remove solids from flow while system is
excavating spoil.
 Operates in such a manner that re-circulated or excess fluid can be discharged safely and
with negligible remaining fines.
 Overall control system that enables remote control of all main operating functions of system
from one location, either at surface or within jacking shaft.
 Main jacking pit capable of exerting uniform load to casing pipe at a speed commensurate
with speed of excavation advance.
 Set jacking hydraulics to relieve pressure at maximum safe working capacity of casing pipe.

4.5.4 Grouting of Annular and voids

To prevent future settlement it shall be ensured that filling of annular around the pipe and any
void(s)/gaps with suitable cement grout is performed.

4.6 After Construction

After construction, all details of the completed NDRC work shall be collected and submitted to the
Road Authority including test certificates and relevant Contractor’s notes/reports. A checklist of
required information and documentation is given in Appendix D.

4.6.1 Inspection and testing

Pipe inspection and testing shall be carried out according to the Client’s specifications.
An infiltration test of the permanent construction should be carried out to verify that the pipeline,
joints/connections are water tight. The infiltration test shall first be carried out after any dewatering
is stopped and the groundwater has attained normal levels.
If requested by the DMAT, CCTV inspections should be carried out to ensure that the inside of the
pipeline is structurally sound. Man entry pipes shall be visually inspected only. The inspection
should include:
 Line and level
 Joints
 Damage
 Deformation
 Connections
 Linings and coatings
Any leaks shall be recorded, and repaired as appropriate. All records should be submitted to the
DMAT. The grouting will also need to be checked and certified as applicable to the ground
conditions.

4.6.2 Site clearance and decommissioning

After completion, the working areas shall be cleared and reinstated to their previous condition. All
equipment, materials shall be removed and excess spoils and waste shall be disposed of in an
approved and environmentally suitable way.
Working shafts shall be backfilled with suitable compacted materials in accordance with the
Specifications. Shoring or other temporary shaft materials shall be removed or cut to a level
minimum 1.5 m under surface level.

PAGE 64

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

 NDRC MANUAL

A checklist should be developed by the Contractor and submitted to the DMAT. Some suggested
points are contained within a checklist in Appendix A.

4.6.3 Monitoring/inspection for long term (latent) defects

The Contractor shall carry out monitoring of ground surface movement, as described in Section
4.5.1, two years after completion and report monthly any changes to the Road Authority.
A visual inspection of the working area and surrounding structures shall be done at the same time
and any defects that may have been a consequence of the NDRC work shall be included in the
report.

4.6.4 QA/QC Methodology

Quality Assurance and Quality Control are key factors in a successful NDRC undertaking. The
Contractor shall implement a Quality Assurance Plan (QAP) outlining proposed points where
quality controls will be performed.
These shall include but not necessarily be limited to:
 Check and approval of all working drawings and method statement.
 Location of any other utilities or structures have been correctly identified and marked.
 Pipe/cable materials conform to specifications and quality documentation from
manufacturer has been acquired.
 Line and level of proposed NDRC have been checked including guidance system.
 Check of machinery and other equipment.
 During installation; check of rate of advancement, drilling pressure, torque, pulling forces,
etc.
 Check of flow and pressure of any drilling fluids or lubrication.
 Amount of soil excavated is registered and checked in conjunction with theoretical values.
 Close observation of the works by operators and foremen eliminates any adverse effect of
unexpected driving condition by fast reacting to such problem, which may result from hitting
unforeseen object or strata interface.
 Any dewatering installations are checked and flow registered.
 Any deviations or unexpected developments are registered and investigated.
 Surface movements are monitored in accordance with this manual.
 After completion the line and level are surveyed and registered and documented.
A minimum requirements checklist to be followed before commencement of works is included in
Appendix A.
All controls and information are to be gathered/documented and kept at the work site for any
inspections.

PAGE 65

04-PROCEDURES FOR UNDERTAKING NDRC FIRST EDITION -DECEMBER 2016

NDRC MANUAL

CITED REFERENCES

1. Horizontal Directional Drilling utility and Pipeline Applications, David A. Willoughby (2005).
2. Abu Dhabi Municipality Sewerage Projects Committee - General specifications for civil
works, Pipeline construction by Non Disruptive method (2003).
3. The Pipe Jacking Association (UK) - "An introduction to pipe jacking and micro-tunnelling
design" (1995).
4. Horizontal Directional Drilling Good Practices Guidelines - 2008 (3rd Edition) USA
5. Standard DWA-A 125E Pipe Jacking and Related Techniques, German Association for
Water, Wastewater and Waste (2008).
6. Microtunneling and Horizontal Drilling Recommendations, FSTT, French Society of
Trenchless Technology (2006).
7. Euronorm EN 12889: Trenchless Construction and Testing of Drains and Sewers.
8. http://www.groundloss.com/theory/#volume-loss.
9. International Society of Trenchless Technology, ISTT - www.istt.com
10. Pipe Jacking Association (UK) - www.pipejacking.org
11. North American Society for Trenchless Technology, USA - www.nastt.org
12. Abu Dhabi Municipality Road Department - Requirements and Recommendations for Non -
Disruptive Road Crossings.
13. Ground Movements around Tunnels in Soft Ground, Z.C. Moh,Daniel H.Ju and
R.N.Hwang,Int.symposium on Geotechnical Aspects of Underground Construction in soft
ground, April 15-17,1996,London.
14. AD-D-02 Geotechnical Investigation and Design.
15. DOT-M-08 Environmental, Health and Safety Manual for Road Projects.
16. DOT-M-05 Quality Assurance and Quality Control Requirements for Road Projects.
17. CIRIA Project Report No. 30, 1997, UK.

Page 66
REFERENCES FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

APPENDIX A: CHECKLISTS FOR SUBMITTALS

A.1 Checklist of submittals for approval of the preliminary
design
The following information or documents shall as a minimum be submitted for preliminary
approval (pre-tender) of NDRC design.

Nr Requirement
1 NDRC Application form
2 Approval letter from Abu Dhabi Town Planning

Drawings:
3 Map of site location
4 Plan of line, level and diameter
5 Profile section of proposed drive
6 Plan of work site area showing working shaft locations and sizes
7 Plans showing other utilities

Geotechnical:
8 Preliminary sources study
9 Ground investigation factual and interpretative reports
10 Profile section showing soil conditions along the proposed drive

Page 67
APPENDIX A FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

A.2 Checklist of submittals for approval of construction

The following information or documents shall as a minimum be submitted for final approval
of design and approval of construction:

Nr Requirement
1 NDRC Application form
2 Approval letter from Abu Dhabi Town Planning
Approval request letter from design consultant for design and supervision
3
addressed to highway section (Arabic)
4 Approval request from Contractor with confirmation of the Sub Contractor name
Undertaking letters from the Client, main Contractor and NDRC Sub Contractor
5
as per DMAT forms
Method statement including detailed description of method, sequencing and
6 program of work, key qualifications and references, list of equipment and
materials, ground water control, safety procedures and risk assessment

Drawings:
7 Map of site location
8 Plan of line, level and diameter
9 Profile section of proposed drive
10 Plan of work site area showing working shaft locations and sizes
11 Plans showing other utilities
12 Details of shafts including entry and exit seals

Calculations:
13 Design calculations of pipe materials with max. permissible forces
14 Design calculations of shafts
15 Surface movement calculations

Geotechnical:
16 Preliminary sources study
17 Ground investigation factual and interpretative reports
18 Profile section showing soil conditions along the proposed drive

No Objection Certificates (NOC) from utility agencies, property owners, police

19
and other relevant authorities

20 Bank guarantee (6000 AED per m length )

Page 68
APPENDIX A FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

A.3 Checklist of Potential H&S Hazards & Risks

The following are considered potential Health and Safety risks for NDRC work to be
considered by the Contractor. This list is not exhaustive and is to be expended depending
on site conditions/location

Nr Potential Risk
1 Road User/Public Awareness of Works
2 Site Workers Training/Ability
3 Confined Spaces
4 Damage to Existing Utilities
5 Damage to Equipment
6 Unexpected Ground Conditions
7 Failure of Traffic Management System
8 Surface Heave
9 Surface Settlement
10 Excavation collapse
11 Poor maintained equipment
12 Adjacent structures
13 Adjacent works

Page 69
APPENDIX A FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

A.4 Checklist of Authorities for NOCs

The following is a list of Authorities who will need approaching for approval to dig. This list is
not exhaustive.

Nr Items

1 Abu Dhabi City Municipality, Town Planning & Survey Directorate

2 Abu Dhabi City Municipality, Roads Section
3 Abu Dhabi City Municipality Public Gardens Directorate
4 Al Ain City Municipality
5 Western Region Municipality
6 Abu Dhabi Transmission and Dispatch Co.(TRANSCO) (Water and Electric)
7 Abu Dhabi Distribution Company, ADDC (Water & Electricity Authority)
8 Abu Dhabi Sewage Services Company, ADSSC (Sewer)
9 Etisalat (Telephone Authority)
10 DU (Telephone)
11 GASCO (Gas Authority)
12 Dolphin Energy (Gas Authority)
13 ADNOC (Oil)
14 TAKREER (Oil)
15 Abu Dhabi Monitoring & Control Centre (MCC)
16 GHQ Armed Forces (Fibre optic cables)
17 Critical National Infrastructure Authority, CNIA

Page 70
APPENDIX A FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

A.5 Checklist of QAQC Issues

The following is a list of potential QAQC issues to be checked and signed off before
construction commences.

Nr Items
The supervisor has previous experience with the specific construction method
1
being used
The personnel performing the operations have the relevant expertise/prior
2
knowledge
3 The manufacturer’s instructions are being followed
4 Set up procedures are complete
5 The materials are ready and to hand before commencement
The supervisor has previous experience with the specific construction method
6
being used
The personnel performing the operations have the relevant expertise/prior
7
knowledge
8 The manufacturer’s instructions are being followed

Page 71
APPENDIX A FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

A.6 Checklist of Post-Construction Checks

The following is a list of potential issues to be checked and signed off following construction.
This list is not exhaustive and is to be expended depending on site conditions/location.

Nr Items
1 Have all excavations been backfilled?
2 Have all materials been removed from the site area?
3 Has all machinery been removed from the site area?
4 Has all traffic management signage and protection been removed?
5 Is the surface in a clean state and as per the commencement of the works?
6 Has all vegetation been replaced/reinstated?
7 Have all excavations been backfilled?

Page 72
APPENDIX A FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

APPENDIX B: FORMS AND EXAMPLES OF APPLICATION FOR

NDRC WORKS
B.1 Required forms and examples of letters
The following forms and letters must accompany all applications for undertaking NDRC
work.
1. Approval request letter from design consultant for design and supervision addressed
to the highway section (Arabic)
2. Approval request from the Contractor with confirmation of the Sub-Contractor name.
(Example Conditions of NOC is provided)
3. Undertaking letters from the client, main Contractor and NDRC Sub-Contractor as
per DMAT forms (Arabic examples provided, since Arabic is the governing
language)
4. Bank Guarantee

Important Note:
All the presented forms in this Appendix are provided as examples only. All parties shall
adopt the current procedures and forms as required by the DMAT, irrespective of being
exactly conforming to the sample documents/examples provided herein.
DMAT has the right to modify the current procedures/forms at any time, and this will be
declared to the concerned parties.

Page 73
APPENDIX B FIRST EDITION -DECEMBER 2016
 ‫‪NDRC MANUAL‬‬

‫شروط عدم الممانعة على أعمال الحفر باألنفاق‬

‫‪. :‬‬ ‫المشروع‬

‫‪:‬‬ ‫الجهة المالكة‬

‫‪:‬‬ ‫المقاول الرئيسي‬

‫‪:‬‬ ‫مقاول الباطن‬

‫مقاول الحفر باألنفاق ‪:‬‬

‫تفاصيل الحفر‪:‬‬

‫الحد األدنى للعمق (من‬

‫طول النفق تحت‬ ‫رقم‬
‫سطح اإلسفلت إلى قمة‬ ‫الحد األقصى لقطر النفق‬ ‫مكان التقاطع‬
‫الطريق‬ ‫التقاطع‬
‫األنبوب)‬
‫‪1‬‬

‫الشروط‪:‬‬

‫‪ -1‬يجب الحصول على موافقة كافة جهات الخدمات المعنية قبل المباشرة بأي أعمال بالموقع ‪.‬‬
‫‪ -2‬يمنع منعاً باتا ً تنفيذ أو تفويض أي أعمال موضوع الموافقة ألي مقاول آخر غير مقاول الحفر باألنفاق المعتمد أعاله‬
‫حتى ولو كان المقاول الرئيسي إال بموافقة دائرة الشؤون البلدية والنقل‪.‬‬
‫‪ -3‬إن (عدم الممانعة) تقتصر فقط على أماكن الحفر الموضحة أعاله وحسب التفاصيل المبنية عندها ‪.‬‬
‫‪ -4‬يتعهد المقاول ومقاول الباطن بكفاية وصحة ومصداقية المعلومات المقدمة في تقرير فحص التربة باعتباره الوثيقة‬
‫الفنية االساسية التي يبنى عليها تصميم وتنفيذ االعمال وطبقا لمتطلبات دليل اختبارات التربة والتصميم الجيوتقني‬
‫المعتمد لدى دائرة الشؤون البلدية والنقل‪.‬‬
‫‪ -5‬على المقاول عمل حفر جسات في الموقع من نوع )‪(Excavate to locate‬لغرض التأكد من ان المعلومات‬
‫والبيانات الواردة في مخططات الخدمات القائمة)‪(as built drawings‬مطابقة للواقع‪.‬‬
‫‪ -6‬إذا تبين من تقرير التربة الخاص بالموقع وجود طبقة من التربة الضعيفة عند مستوى الحفر‪ ،‬فيتوجب على المقاول‬
‫إجراء تثبيت للتربة قبل البدء في أعمال الحفر‪.‬‬
‫‪ -7‬على المقاول ومقاول الباطن للحفر باألنفاق االلتزام بطريقة العمل المقدمة بدون أي إخالل بخطواتها من حيث تسلسل‬
‫التنفيذ والفترة الزمنية بين كل خط حسب الجدول المرفق ويتحمل مسؤولية أي نتائج نتيجة عدم االلتزام بذلك‪.‬‬
‫‪ -8‬الكفالة البنكية المقدمة ال تمثل تكلفة إصالح الهبوط في حالة حدوثه وإنما هي ضمان لحين انتهاء فترة المراقبة لمنطقة‬
‫الحفر بالدفع األفقي والتكلفة الحقيقية تحدد في حينه مهما بلغت‪.‬‬

‫‪Page 74‬‬
‫‪APPENDIX B‬‬ ‫‪FIRST EDITION -DECEMBER 2016‬‬
 ‫‪NDRC MANUAL‬‬

‫‪ -9‬مدة المراقبة لمنطقة الحفر بالدفع األفقي هي لمدة (سنتين) من تاريخ تأكيد استشاري صيانة الطرق انتهاء األعمال في‬
‫الموقع حسب المواصفات وطريقة العمل المقدمة والمعتمدة‪.‬‬
‫يجب عدم البدء باألعمال إال بعد عمل محضر رسمي بتسليم الموقع (ويشمل مواقع و مناسيب نقاط المراقبة في‬ ‫‪-10‬‬
‫حينه‪ ،‬وصور ملونة لموقع الحفر ) بحضور ممثل دائرة الشئون البلدية والنقل واستشاري المشروع ‪ ،‬واستشاري دائرة‬
‫الشئون البلدية والنقل لصيانة الطرق بالمنطقة والمقاول الرئيسي والمقاول الفرعي ومقاول الحفر‪.‬‬
‫على جهاز اإلشراف (االستشاري‪ /‬الجهة المالكة) التأكد من التزام المقاول ومقاول الباطن بطريقة العمل المقدمة‬ ‫‪-11‬‬
‫وأخذ صور وقراءات لتقدم األعمال منذ بدايتها ومحددات الحفر وتقديمها للدائرة عند إتمام المشروع‪.‬‬
‫‪ -12‬على المقاول ومقاول الباطن للحفر باألنفاق وتحت إشراف االستشاري اتخاذ كافة اإلجراءات التي تضمن بقاء مقدار‬
‫هبوط سطح اإلسفلت ضمن الحد (‪ 6‬ملم) المسموح به‪ ،‬وفي حالة تجاوز الحد المسموح به فيترتب على االستشاري‬
‫إبالغ ممثل دائرة الشؤون البلدية والنقل مباشرة وبدون أي تأخير‪.‬‬
‫‪ -13‬يجب أن ال يقل العمق بين سطح اإلسفلت وأعلى النفق و قطر النفق عن ما تم ذكره في طريقة العمل المقدمة (المبين‬
‫أعاله) والمحقق إلشتراطات دليل العبور غير المتلف للطرق الخاص بالدائرة‪.‬‬
‫‪ -14‬أن ال تقل المسافة بين حافة كل من حفرة الدفع وحفرة االستقبال و حافة الدفان السفلى للطريق (‪ )Sub-Grade‬عن‬
‫خمسة أمتار كحد أدنى‪.‬‬
‫‪ -15‬يجب أن ال يزيد قطر النفق عن القطرالمكتوب بطريقة العمل المعتمدة من الدائرة‪.‬‬
‫‪ -16‬يجب تثبيت نقاط مراقبة هبوط سطح اإلسفلت على شكل شبكة بأبعاد تساوي ‪ 2×2‬متر‪ ،‬ويجب أن تغطي هذه الشبكة‬
‫كامل عرض الطريق على طول النفق وعلى كال جانبيه بمسافة ال تقل عن المسافة بين مركز النفق وبين سطح‬
‫اإلسفلت‪ .‬كما يجب أن يتم أخذ القراءات (تحت إشراف االستشاري‪ /‬الجهة المالكة) قبل البدء بتنفيذ هذه األعمال وأثناء‬
‫التنفيذ (بمعدل ‪ 3‬مرات في كل دورية عمل) وبعد التنفيذ بمعدل مرة واحدة كل شهر على أن تكون النقطة المساحية‬
‫المرجعية (‪ )Benchmark‬على مسافة ال تقل عن ‪ 50‬متر من مكان النفق‪.‬‬
‫‪ -17‬يجب على جهاز اإلشراف (االستشاري‪ /‬الجهة المالكة) تقديم كافة السجالت الخاصة بقراءات نقاط مراقبة سطح‬
‫الطريق بشكل رسمي ودوري كل شهر للدائرة‪.‬‬
‫‪ -18‬يجب اخذ جميع احتياطات األمن والسالمة الالزمة عند حفرتي الدفع واالستقبال وكذلك العالمات التحذيرية المناسبة‬
‫لضمان سالمة المشاة والمركبات ليالً ونهاراً حسب االشتراطات الالزمة من شرطة أبو ظبي ومن الدائرة مع بيان‬
‫أرقام هواتف المشرفين على األعمال وذلك للحاالت الطارئة‪.‬‬
‫‪ -19‬يجب إعادة دفان الحفرتين بعد االنتهاء من العمل على طبقات وإزالة جميع المخلفات من الموقع وإعادة الموقع لما كان‬
‫عليه قبل بدء العمل‪.‬‬
‫‪ -20‬إذا لزم األمر إلجراء عمليات سحب مياه (‪ )Dewatering‬فيجب التأكد من تنفيذها بالطريقة المعتمدة ودون التأثير‬
‫على خواص التربة ‪ ،‬كما يجب معرفة حالة المباني وعناصر البنية التحتية المحيطة وتوثيقها(‪)dilapidatio survey‬‬
‫قبل البدء باألعمال‬

‫‪Page 75‬‬
‫‪APPENDIX B‬‬ ‫‪FIRST EDITION -DECEMBER 2016‬‬
 ‫‪NDRC MANUAL‬‬

‫‪ -21‬التنسيق مع استشاري الدائرة الصيانة بقطاع الطرق والخدمات الفنية المشرف على صيانة المنطقة التي سيتم الحفر‬
‫بها‪.‬‬
‫‪ -22‬تسليم الدائرة نسختين من المخططات لألعمال المنفذة فعليا ً ( ‪ ) AS BUILT‬والمعتمدة من استشاري المشروع بعد‬
‫انتهاء األعمال مرفقة مع خطاب رسمي من استشاري المشروع‪.‬‬
‫‪ -23‬في حالة عدم االلتزام بأي شرط من الشروط سابقة الذكر يتم التعامل مع الكفالة البنكية (‪)Bank Guarantee‬‬
‫بحسب االجراءات المتبعة بدائرة الشئوون البلدية والنقل‪.‬‬

‫نقر أننا قد اطلعنا على الشروط كافة من(‪ )23 -1‬ونؤكد موافقتنا عليها والتزامنا بها وعلى هذا نوقع‪-:‬‬ ‫‪‬‬
‫‪:‬‬ ‫المقاول الرئيسي‬

‫االسم ‪-:‬‬

‫الوظيفة ‪-:‬‬

‫‪:‬‬ ‫مقاول الباطن‬

‫االسم‪:‬‬

‫الوظيفة‪:‬‬

‫مقاول الباطن للحفر باألنفاق‪:‬‬

‫االسم‪:‬‬

‫الوظيفة‪:‬‬

‫يجب أن يكون الشخص الموقع مخول بالتوقيع مع إرفاق نسخة من هذا التخويل‬

‫‪Page 76‬‬
‫‪APPENDIX B‬‬ ‫‪FIRST EDITION -DECEMBER 2016‬‬
 ‫‪NDRC MANUAL‬‬

‫إقرار وتعهد‬

‫المشروع ‪---------------------:‬‬

‫نقر نحن شركة‪ /‬دائرة ‪ -------------------‬بصفتنا مالك المشروع بأنه في حالة حدوث أي هبوط‬
‫أو أضرار في الطرق او منشآت الطرق عن ما هو مسموح به حسب شروط دائرة الشئون‬
‫البلدية والنقل بالمنطقة التي يقوم بها المقاول الرئيسي‪ /‬شركة ‪ --------------‬ومقاول الحفر‬
‫بطريقة الدفع األفقي نوع ‪ ------------‬المعتمدة من قبلنا شركة ‪ ---------‬لقطر كلي مقداره ‪---‬‬
‫‪ ----------‬مم فإننا سنقوم بإبالغ دائرة الشئون البلدية والنقل فوراً بذلك‪ ،‬ونتعهد بإجراء‬
‫اإلصالحات الالزمة طبقاً لمواصفات دائرة الشئون البلدية والنقل أو خصم تكاليف اإلصالح من‬
‫المقاول الرئيسي لصالح دائرة الشئون البلدية والنقل فور حدوث الهبوط وفور طلب دائرة‬
‫الشئون البلدية والنقل لذلك دون إبطاء أو مراجعة ودفع التعويضات عن أي حادث يسببه هذا‬
‫الهبوط‪.‬‬
‫وهذا تعهد وإقرار منا بذلك‪.‬‬

‫مالك المشروع‪----------- :‬‬

‫دائرة‪ /‬شركة ‪--------------------‬‬

‫االسم ‪:‬‬
‫الوظيفة‪:‬‬
‫التوقيع والختم‪:‬‬

‫اليوم والتاريخ‬

‫يجب أن يكون الشخص الموقع مخول بالتوقيع مع إرفاق نسخة من هذا التخويل‬

‫‪Page 77‬‬
‫‪APPENDIX B‬‬ ‫‪FIRST EDITION -DECEMBER 2016‬‬
 ‫‪NDRC MANUAL‬‬

‫إقرار وتعهد‬

‫المشروع ‪---------------------:‬‬

‫نقر نحن شركة ‪ ----------------‬بصفتنا المقاول الرئيسي للمشروع أعاله والمملوك للسادة‪-- /‬‬
‫‪ -----------‬بأنه في حالة حدوث أي هبوط أو أضرار في الطرق او المنشآت بمنطقة ‪---------‬‬
‫على طريق ‪ -------‬التي تقوم بها شركة ‪ ------------‬بصفتها مقاول الحفر بطريقة الدفع‬
‫األفقي نوع ‪ ------------‬لقطر كلي مقداره ‪ ------‬مم والمعتمدة من قبلكم نتيجة عمليات‬
‫الحفر فيها او جوارها فإننا سنقوم بإبالغ دائرة الشئون البلدية والنقل فوراً بذلك‪ ،‬ونتعهد بإجراء‬
‫اإلصالحات الالزمة طبقاً لمواصفات دائرة الشئون البلدية والنقل أو دفع كافة تكاليف اإلصالح‬
‫لصالح دائرة الشئون البلدية والنقل فور حدوث الهبوط وفور طلب دائرة الشئون البلدية والنقل‬
‫لذلك دون إبطاء أو مراجعة ودفع التعويضات عن أي حادث يسببه هذا الهبوط‪.‬‬
‫وهذا تعهد وإقرار منا بذلك‪.‬‬

‫عن شركة ‪--------------------‬‬

‫االسم ‪:‬‬
‫الوظيفة‪:‬‬
‫التوقيع والختم‪:‬‬

‫اليوم والتاريخ‬

‫يجب أن يكون الشخص الموقع مخول بالتوقيع مع إرفاق نسخة من هذا التخويل‬

‫‪Page 78‬‬
‫‪APPENDIX B‬‬ ‫‪FIRST EDITION -DECEMBER 2016‬‬
 ‫‪NDRC MANUAL‬‬

‫إقرار وتعهد‬

‫المشروع ‪---------------------:‬‬

‫نقر نحن شركة ‪ ----------------‬بصفتنا مقاول الحفر بطريقة الدفع األفقي نوع ‪ -----------‬لقطر‬
‫كلي مقداره ‪------‬مم لصالح المالك ‪ ------------‬والمقاول الرئيسي‪ ---------------‬بأنه في حالة‬
‫حدوث أي هبوط أو أضرار في الطرق او المنشآت بالمنطقة التي نقوم بعمليات الحفر فيها أو‬
‫جوارها بمنطقة ‪---------‬على طريق ‪ ---------‬فإننا سنقوم بإبالغ دائرة الشئون البلدية والنقل‬
‫فوراً بذلك‪ ،‬ونتعهد بإجراء اإلصالحات الالزمة طبقاً لمواصفات دائرة الشئون البلدية والنقل أو دفع‬
‫كافة تكاليف اإلصالح لصالح دائرة الشئون البلدية والنقل فور حدوث الهبوط وفور طلب دائرة‬
‫الشئون البلدية والنقل لذلك دون إبطاء أو مراجعة ودفع التعويضات عن أي حادث يسببه هذا‬
‫الهبوط‪.‬‬
‫وهذا تعهد وإقرار منا بذلك‪.‬‬

‫عن شركة ‪--------------------‬‬

‫االسم ‪:‬‬
‫الوظيفة‪:‬‬
‫التوقيع والختم‪:‬‬

‫اليوم والتاريخ‬

‫يجب أن يكون الشخص الموقع مخول بالتوقيع مع إرفاق نسخة من هذا التخويل‬

‫‪Page 79‬‬
‫‪APPENDIX B‬‬ ‫‪FIRST EDITION -DECEMBER 2016‬‬
 NDRC MANUAL

Conditions for NOC for Micro-tunnelling Works

Project:
Owner Authority:
Consultant:
Contractor:
Micro-tunnelling Works Contractor:
Excavation Details:
No. of Crossing Maximum Tunnel Minimum Depth Tunnel Length
crossings Location Diameter (From Asphalt Under the
Surface to the Top Road
of the Pipe)

Conditions:
1. Obtain approval of all concerned services’ authorities prior to proceeding with any
works in the site.
2. It is “strictly” forbidden to carry out or delegate any works subject of the approval to
any other Contractor other than the above approved Contractor for carrying out
micro-tunneling excavation, even if he is the main Contractor, without DMAT
approval, where bank guarantee will be seized in case you fail to commit to the
above mentioned.
3. The (NOC) is limited only for the above indicated works’ areas, and in accordance to
the details shown next to them.
4. The Contractor and Subcontractor undertake that the provided geotechnical
information are enough, credible, and up-to-date and are as per the requirements of
the Department Geotechnical Manual.
5. The contractor shall verify the information given in the site as built drawings by
excavating to locate the existing utilities or any other objects at site.
6. If the site geotechnical report shows a layer of weak soil at the excavation level, the
Contractor should do stabilization to the soil prior to commence the crossing works.
7. The micro-tunneling Contractor and Sub-Contractor, should commit to the submitted
working method without violating its steps.
8. The submitted bank guarantee does not represent the cost of repair of ground
subsidence in the case of occurrence. It is a guarantee until the end of the monitoring
period of supervising the excavation area by micro-tunnelling and the actual cost will
be determined at the repair time, no matter how much it would be.

Page 80
APPENDIX B FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

9. The monitoring period of micro-tunnelling area is (two years) starting from the date
of the Consultant confirmation of completion of maintenance works on site according
to the specifications and to the submitted and approved working method.
10. Works should not be commenced unless an official site handing over record is made
(including the control points’ baseline levels and locations at that time, as well as
colored photos for the excavation location) in the presence of the project Consultant,
the DMAT road maintenance Consultant in the area, the main Contractor and the
NDRC Contractor.
11. The undersigned project Consultant staff should make sure of the Contractor and the
Sub-Contractor commitment to the submitted work method, and retain photos for the
work phases and record of full data and readings of the excavation machine starting
from commencement date to completion date, a copy of which is to be submitted to
DMAT after completion of work.
12. Under the supervision of the Consultant, the Contractor and microtunneling
excavation Sub-Contractor shall make arrangements required to maintain asphalt
surface subsidence level within the limit allowed (6mm). In case that allowed limit is
being exceeded; the Consultant should inform DMAT directly and without any delay.
13. The depth between asphalt surface and the top of the tunnel should not be less than
what is stated in the submitted work method, which will realize the requirements of
the DMAT Manual of NDRC for utilities. .
14.
15. The distance from the edge of each of the push pit and the receiving to the road
(sub-grade) edge should not be less than 5.0 m minimum.
16. The tunnel diameter should not exceed what is stated in the submitted work method.
17. The asphalt surface subsidence control points should be fixed at a shape of a grid
with dimensions of 2x2 m. This grid should cover the road full width along the tunnel
at both sides at a distance not less than the distance between the tunnel center and
the asphalt surface. Also readings should be taken (under the Consultant/Owner
Authority supervision) prior to commence and during carrying out these works (at rate
of 3 times for each work shift), and after execution, provided that the benchmark
should not be less than 50.0 m from the tunnel location.
18. The supervision staff (Consultant/Owner Authority) should submit all the records
related to the road surface control points readings, officially and regularly every
month to the DMAT..
19. All security and safety precautions should be taken at the push pit and the receiving
pit, and also the suitable warning signs to ensure the safety of the pedestrians and
vehicles day and night according to the necessary conditions of Abu Dhabi Traffic
Police and DMAT. The mobile phone numbers of the works foremen and supervisors
shall also be presented for emergency use.
20. The two pits’ should be re-filled after work completion on layers and to remove all the
debris and to fully reinstate the site.

21. If dewatering works are inevitable, they should be carried out by the approved
way and without affecting the soil characteristic A dilapidation survey shall be
carried out to record the reference status of the surrounding private and
public properties.

Page 81
APPENDIX B FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

22. The Consultant and the Contractor shall coordinate with the Maintenance Consultant
of the DMATwho is supervising the maintenance of the area in which the works will
take place.
23. Two copies of the “As Built ” for the executed works shall be approved by the
project Consultant after work completion and be submitted to the DMAT, along with
an official letter from the project Consultant.
24. In case any of the above conditions was violated, the relevant DMAT rules
concerning the bank guarantee shall be applied.

We recognize that we have learned all the conditions (1-23) and confirm our agreement and
our commitment to them, and we accordingly sign:

Consultant:
Name:
Position:

Contractor:
Name:
Position:

Micro-tunneling Sub-Contractor:
Name:
Position:

Notes:
The above is an example form and may not be the one to be adopted as a translation to the
official Arabic form.
As previously indicated, the Arabic text of the form to be adopted by the DMAT shall govern,
and the English version is only provided for guidance to non-Arabic speakers.
________________

Page 82
APPENDIX B FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

APPENDIX C: CHECKLISTS FOR MONITORING DURING

CONSTRUCTION

C.1 Daily Requirements

The following checklist contains the minimum requirements of monitoring and data
collection, by the contractor or his sub-contractor, on a daily basis during construction. This
shall comprise , but not necessarily be limited to:

Nr Requirement
1. Numbers of personnel and equipment on site (names, positions, etc.)
2. Inspection of work site fencing, traffic barriers, signs, safety checks, etc.
3. Installed length of pipe (types, times etc.)
4. Line and level measurements
5. Any vertical or horizontal deviations from planned line
6. Instrumentation readings of jacking, drilling or pulling forces
7. Slurry or bentonite usage and pressure readings
8. Amount and nature of excavated soil or spoils removed
9. Monitoring reports of surface movement
10. Check and inspection of delivered materials
11. Check of machinery and other equipment
12. Any accidents or unexpected events - their cause and actions taken

All reports shall be submitted by the contractor and approved and signed by the supervising
Consultant.

Page 83
APPENDIX C FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

APPENDIX D: CHECKLISTS FOR MONITORING AFTER

CONSTRUCTION

D.1 After Construction

The following checklist contains the minimum requirements of monitoring and data collection
on a daily basis during construction. This should be collated and submitted by the Contractor
or Sub-Contractor and shall comprise , but not necessarily be limited to:

Nr Requirement
1. Line and level measurements updated on As Built drawings
2. Infiltration test documenting the pipeline is water tight, including details on the
testing analysis and techniques
3. CCTV or other report of internal inspection, highlighting any deformation or
irregularities (in DVD format)
4. Documentation of installed pipe materials (manufacturer, type, etc.)
5. Any vertical or horizontal deviations from planned line (to be shown in profile
sections)
6. Instrumentation readings of jacking, drilling or pulling forces (report format)
7. Slurry or bentonite use and pressure readings (report format)
8. Quantities of excavated soil or spoils removed
9. Monitoring reports of surface movement, including details on the methods used
for calculation
10. Reports of accidents or unexpected events - their cause and actions taken
11. Post-construction site survey, including electronic copy
12. Construction photographs and/or video as appropriate
13. Documentation of correct backfilling and compaction of shafts including
compaction test results
14. Report showing that work site has been cleared and all waste removed

All reports shall be submitted by the contractor and approved and signed by the supervising
Consultant.

Page 84
APPENDIX D FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

APPENDIX E: TUNNELLING AND PIPE JACKING

Page 85
APPENDIX E FIRST EDITION -DECEMBER 2016
 NDRC MANUAL

Internal dimensions for pipe jacks and tunnels below 3.m diameter and indicative drive lengths

Page 86
APPENDIX E FIRST EDITION -DECEMBER 2016