Method Statement - D200 Expressway Crossing by HDD and Pipe Ramming - English

METHOD STATEMENT

D200 PIPELINE EXPRESSWAY CROSSING

BY HDD AND PIPE RAMMING TECHNIQUE

*************

LOCATION: HCMC – DAU GIAY EXPRESSWAY

DOCUMENT NO.: DTS – HDD.07/15

A 10/04/15 Issued for Approval

REV DATE DESCRIPTION BY CHECK APPROVED CLIENT CA

This document and information contained in it is the sole property of DTS and may not be exploited, used, copied duplicated or reproduced in

any form or medium whatever without the prior permission of DTS.

METHOD STATEMENT – D200 STEEL PIPE EXPRESSWAY CROSSING


Prepared by: Deltatech Technical Services JSC Page 2

INDEX

CHAPTER I - GENERAL I.1. Responsibility ............................................................................................... page 05

I.2. Project description ........................................................................................ page 05

I.3. Project scope of work ................................................................................... page 06

CHAPTER II - METHODOLOGIES

II.1. WORK ANALYSIS .................................................................................... page 07

II.1.1. Site survey and considerations ................................................................ page 07

II.1.2. Potential problem and solution ................................................................. page 08

II.2. PREPARATION.......................................................................................... page 10

II.2.1. Equipment, tools, material and consumables ........................................... page 10

II.2.2. Site organization ....................................................................................... page 11

II.2.2.1. Organization chart ................................................................................. page 11

II.2.2.2. Personnel’s job description ................................................................... page 12

II.3. HORIZONTAL DIRECTIONAL DRILLING (HDD) ............................... page 15

II.3.1. Pilot drilling .............................................................................................. page 15

II.3.2. Drill path and drilled hole size ................................................................. page 16

II.3.3. Drilling fluid ............................................................................................. page 17

II.3.3.1. Drilling fluid function ........................................................................... page 17

II.3.3.2. Mixing procedure .................................................................................. page 17

II.3.3.3. Original ...................................................................................................page 17

II.4. PIPE RAMMING ........................................................................................ page 17

II.4.1. Setting up .................................................................................................. page 17

II.4.2. Pipe ramming technique ........................................................................... page 18

II.4.3. Main parts and functions of pipe ramming hammer system .................... page 21

II.4.3.1. Main parts .............................................................................................. page 21

II.4.3.2. Main functions ....................................................................................... page 22

II.4.3.3. Soil cleaning .......................................................................................... page 23

II.4.3.4. Pneumatic pipe ramming hammer structure .......................................... page 24

II.4.3.5. Pipe ramming hammer selection ........................................................... page 24

II.4.3.6. Requirement for steel product pipe ....................................................... page 25

II.4.3.6.1. Pipe outside cleaning .......................................................................... page 25

II.4.3.6.2. Wall thickness .................................................................................... page 25

II.5. EARTH/FOUNDATION WORK FOR DRILLING EQUIPMENT .......... page 26

II.5.1. Earth work in flat ground ......................................................................... page 26

II.5.2. Earth/foundation work in road shoulder ................................................... page 26

II.6. OVERCOMING ACTIONS WHEN DRILLING/RAMMING PROBLEMpage27

CHAPTER III - WORK PLAN

III.1. SUGGESTED ACTIVITIES ..................................................................... page 28

Crossing No.1 Km0+100, Pk4-ITS008-G-111-D: 44m ...................................... page 28








Crossing No.6 Km10+920, Pk4-ITS008-G-128-D: 22m .................................... page 33




Crossing No.10 Km22+720, Pk4-ITS008-G-223-D: 16m .................................. page 37




Crossing No.14 Km23+330, Pk4-ITS008-G-224-D (1): 60m ............................ page 41
























III.2. WORK PLAN ............................................................................................ page 65

CHAPTER IV - SAFETY CONTROL

IV.1. Personnel check ......................................................................................... page 70

IV.1.1. Personality check .................................................................................... page 70

IV.1.2. Protection check ...................................................................................... page 70

IV.2. Working base check ................................................................................... page 70

IV.2.1. Working trench check ............................................................................. page 70

IV.2.2. Foundation check .................................................................................... page 70

IV.3. Equipment/tools check ............................................................................... page 71

IV.3.1. Function check ........................................................................................ page 71


IV.4. Material/consumables check ...................................................................... page 71





IV.5. RISK ASSESSMENT ................................................................................ page 71

IV.5. SET UP AND MAINTAIN SAFETY ....................................................... page 73

CHAPTER V - QUALITY CONTROL

V.1. Document control ........................................................................................ page 74

V.2. Material/consumables control ..................................................................... page 74

V.3. Equipment/tools control .............................................................................. page 74

V.4. Drilling/ramming control ............................................................................ page 75

V.5. Welding work control.................................................................................. page 75

Table 1 – Working locations ............................................................................... page 06

Table 2 – Existing and consideration ................................................................. page 07

Table 3 – Potential problem and solution ........................................................... page 09

Table 4 – List of equipment, tools, material and consumables ........................... page 11

Table 5 – Plan for a crossing .............................................................................. page 66

Table 6 – Project general plan ........................................................................... page 68




CHAPTER I

GENERAL

I.1. Responsibility

- Employer: Vietnam Expressway Corporation (VEC).

- Contractor: Toshiba & Hitachi & Itochu Joint Venture.

- Drilling sub-contractor: Deltatech JSC.

I.2. Project description

Drilling sub-contractor required to install D200 galv. steel pipes across HCM –

Long Thanh – Dau Giay expressway at locations as in following table:

No. Position, reference

drawing unit Q’ty No.

Position, reference

drawing unit Q’ty

01 Km0+100, Pk4-

ITS008-G-111-D M 44 20

Km34+500, Pk4-

ITS008-G-326-D m 24

02 Km0+140, Pk4-

ITS008-G-111-D M 45 21

Km34+615, Pk4-

ITS008-G-326-D m 28

03 Km0+720, Pk4-

ITS008-G-112-D M 18 22

Km37+200, Pk4-

ITS008-G-330-D m 30

04 Km4+000, Pk4-

ITS008-G-117-D M 33 23

Km40+940, Pk4-

ITS008-G-416-D (1) m 27

05 Km6+150, Pk4-

ITS008-G-121-D M 19 24

Km40+940, Pk4-

ITS008-G-416-D (2) m 29

06 Km10+920, Pk4-

ITS008-G-128-D M 22 25

Km41+360, Pk4-

ITS008-G-417-D m 30

07 Km11+400, Pk4-

ITS008-G-129-D M 30 26

Km43+650, Pk4-

ITS008-G-421-D m 20

08 Km14+500, Pk4-

ITS008-G-211-D M 22 27

Km43+870, Pk4-

ITS008-G-421-D m 20

09 Km22+380, Pk4-

ITS008-G-222-D M 19 28

Km45+250, Pk4-

ITS008-G-423-D m 21

10 Km22+720, Pk4-

ITS008-G-223-D M 16 29

Km49+000, Pk4-

ITS008-G-429-D m 16

11 Km22+800, Pk4- M 20 30 Km49+250, Pk4- m 19




ITS008-G-223-D ITS008-G-429-D (1)

12 Km23+230, Pk4-

ITS008-G-224-D M 47 31

Km49+250, Pk4-

ITS008-G-429-D (2) m 16

13 Km23+270, Pk4-

ITS008-G-224-D M 40 32

Km52+170, Pk4-

ITS008-G-434-D m 18

14 Km23+330, Pk4-

ITS008-G-224-D (1) M 60 33

Km52+430, Pk4-

ITS008-G-434-D (1) m 18

15 Km23+330, Pk4-

ITS008-G-224-D (2) M 46 34

Km52+430, Pk4-

ITS008-G-434-D (2) m 18

16 Km23+445, Pk4-

ITS008-G-224-D M 24 35

Km54+500, Pk4-

ITS008-G-438-D m 32

17 Km23+790, Pk4-

ITS008-G-224-D M 16 36

Km54+920, Pk4-

ITS008-G-440-D m 19

18 Km24+110, Pk4-

ITS008-G-311-D M 16 37

Km54+980, Pk4-

ITS008-G-441-D m 43

19 Km24+950, Pk4-

ITS008-G-312-D M 21

Table 1 – Working locations

I.3. Project scope of work

D200 galv. steel pipes installed by a combination technique, which horizontal

directional drilling (HDD) done first to get the exact way and pipe ramming

will followed then to insert D200 pipe to complete installation work. Generally,

D200 pipe will go across the expressway at -2m level from road surface.

However, in some cases the pipes can be go lower than that level for safety

requirement:

+ Number of crossing: 37

+ Total length: 986m

+ Construction site condition: As survey.




CHAPTER II

METHODOLOGIES

II.1. WORK ANALYSIS

II.1.1. Site survey and considerations

Site survey report done by Deltatech’s survey team shows soil condition, obstacles,

adjacent constructions, site entrance,… at every crossing so that drilling team can

decide suitable construction methods after consideration for each crossing as

following table:

Existing Consideration

1. Drill length From 16m to 60m (as

designed)

Technique shall be applied:

*1st step: Horizontal

directional drilling (HDD)

*2nd

step: Pipe ramming

2. Drill depth -2m min. (as designed) Keep deeper than road layer

3. Ground structure

*0-2m: road structure

*1.2-2m: filled material

(sand, soil, gravel,…)

*>2m: natural soil, with

stone or gravel at some

crossings

Carefully survey to get

essential information for

drilling procedure

4. Adjacent

constructions

Asphan road layer, road

shoulder, safety fence

*Keep drill path at a safe

distance

*Safety supervision at all time

5. At-site electric No Generator shall be mobilized

6. At-site fresh water No Mobile water tanker required

7. Dumping area No Move to required place

8. Entrance Limited From expressway

9. Accommodation No Set up mobile camp

Table 2 – Existing and consideration




II.1.2. Potential problem and solution

Drilling team’s discussions focus on site existing objects done to point out potential

problem and solution as Table 3 – Potential problem and solution. Major concerns are

the following:

- Keeping safe for all working activities.

- Mobilization and demobilization shall be in time.

- Maximizing working time in raining days.

Safety and management help to control drilling work so that the following

requirements can be satisfied:

- Drilling equipments shall be set up on adequate level so that drill path can be

within designed.

- D200 galv. steel pipe shall be welded and inserted into drilled hole easily.

Potential

problem

1. For safety:

- Unsafe activities (mobilization/demobilization, walking, moving

tools,…) when work across expressway.

- Harming adjacent constructions.

- Unsafe when work in raining time.

2. For work organization:

- Difficulty when work in narrow drilling working space, especially in

high level road shoulder.

- Taking time when work or moving between construction sites due to

expressway traffic regulations, especially in case of emergency.

- Ground problem: Hard ground condition with rock, stone, gravel,…

can create many problem when drilling.

3. For management:

Poor management activities, including supervision and documentation

due to far distances between construction sites.




Solution

1. For safety:

- Risk assessment and safety training for all construction personnel.

- Set up and maintain good cooperation with expressway management

authority:

+ Prepare and explain working procedure in details.

+ Understand cooperation procedure for emergency cases in

expressway.

+ Keep contacted with expressway authority at all working time.

- Set up protection when work in raining time or stop work.

2. For work organization:

- Prepare wide and strong enough working base by earth/foundation

work, sand bags,… a steel frame shall be set up at road shoulder for

drilling equipments laying and work.

- Set up a mobile work group, including vehicle, equipment, personnel

ready for mobilization or demobilization at all time.

- Carefully checking material, consumables, equipment condition

before mobilization, including spare for problem.

- Prepare at-site equipment maintenance plan for emergency cases.

- Overtime working, if required.

- Discuss with the Employer/Contractor to find out possible method,

including changing location, drill depth,… to overcome ground

condition problem.

3. For management:

- Set up mobile offices with staff available at site during construction.

- Carefully study working condition and prepare preventive action to

eliminate risk, problem.

Table 3 – Potential problem and solution




II.2. PREPARATION

II.2.1. Equipment, tools, material and consumables

In order to get the job done in time, the following shall be prepared and mobilized to

the sites:

No. Description Capacity Unit Q’ty

I Equipment, tools

1 Drilling machine D24x26 115hp Set 01

2 Drilling fluid mixing tank 5000 lit Set 02

3 Digitrak F5 locator 25,9m Set 01

4 BH190 pneumatic pipe-ramming

hammer 1500KN Set 01

5 Air compressor 0.7MPa,

6m3/min Set 01

6 Guide rail U200 steel Set 01

7 Leveling instrument 0.8m long Set 01

8 Chain block 3 ton Set 02

9 Tensioner 1 ton Set 02

10 Laser pointer 15w Set 01

11 Walkie-talkie 5w Set 02

12 Excavator

0,4m3 Ea. 01

13 Diesel pump 30m3/h Ea. 01

14 Generator 30KVA Ea. 01

15 Welding machine 250A Ea. 02

16 Grinding machine 15kW Ea. 02

17 Cargo crane 10 tonne Ea. 01




18 Diesel winch 1 tonne Ea. 01

19 Steel U200, I700 Ton 4

20 Wooden pile D150x3000 Ea. 150

21 Mobile accommodation camp 2mx3m Ea. 02

II Material and consumables

1 D200 galvanized steel pipe Sch40 M 1000

2 Bentonite USA Ton 10

3 Additives USA Ton 01

4 Welding consumables Japan Ton 0,5

5 Diesel oil Litter 2000

6 Hydraulic oil Shell Litter 600

7 Fuel Litter 400

Table 4 – List of equipment, tools, material and consumables

II.2.2. Site organization

II.2.2.1. Organization chart

SITE MANAGER

DRILLING

TEAM 1&2

CONSTRUCTION

SUPERVISOR 1&2

EQUIPMENT

TEAM 1&2

GENERAL LABOUR

TEAM 1&2 SURVEY

TEAM

LOGISTIC/

ADMIN 1&2 SAFETY

SUPERVISOR 1&2




II.2.2.2. Personnel’s job description

1. Site manager

- Prepare working procedures for safety, drilling,… and submit the

Employer/Contractor for approval.

- Take part in meeting for work permit held by the Employer.

- Set up and maintain information network from customer, employer to drilling

team at all working time to make sure that customer’s requirements shall be

done in the their owned manner.

- Contact with local government, residence related with construction sites to get

the support for construction work.

- Risk assessment for all work and carry out safety training, meetings for

construction personnel.

- Make sure that all personnel, vehicle, equipment, tool, material, consumables

mobilized for work are checked for safety.

- Prepare preventive actions before work execution.

- Organize overcome actions in case of problem, emergency.

- Make sure that all construction personnel understand their owned assignment,

contact network before any work.

- Assign and control safety supervisor’s work, make sure that all work activities

shall be done under safety supervision.

- Assign and control logistic/admin’s work, including: document control,

material supply control, person administration control.

- Assign and control construction supervisor’s work, including: quality control,

schedule control, equipment control, earth/foundation work control.

- Assign and control survey team’s work, including contact with expressway

construction contractor to get more information about road structure.

2. Safety supervisor

- Study working procedures, site survey, analyze risk for all work activities and

support for site manager complete safety procedure.

- Take part in meeting for work permit together with site manager.

- Support for site manager in safety meetings at site.

- Supervises all site activities:




Check for safety all personnel, vehicle, equipment, tool, material,

consumables mobilized to site before and during construction activities.

Advise drilling team safe way to work.

Stop unsafe work and report site manager to avoid problem.

- Prepare daily safety report, submit to site manager.

3. Logistic/admin

- Responsible for documentation at site and office.

- Keep contacted with the Employer and Contractor’s office.

- Receive list of equipment, tools, material and consumables from site manager

to do preparation.

- Support for site manager in preparation personnel’s certificates, equipment’s

certificates, material/consumables’ certificates, submit to the


- Arrange mobilization/demobilization.

- Prepare time sheet, payment.

4. Construction supervisor

- Support for site manager to control all site activities:

Mobilization/demobilization.

Earth/foundation work.

Welding work.

Drilling work.

Pipe ramming work.

- Check all material/consumables for quality before using for work.

- Check all equipments for function before work.

- Prepare quality control documents at site, get site manager’s signature and

submit to the Employer/Contractor for approval.

- Prepare as-built document, get site manager’s signature and submit to the


- Support for site manager in emergency case.

5. Survey team




- Carry out site survey.

- Report to site manager.

- Take part in discussion with construction team to find out suitable construction

method.

- Contact with expressway construction contractor for more details with road

structure.

6. Drilling team

- Receive work order from construction supervisor.

- Set up safety signs, safety fence as required in safety procedure before working.

- Set up protection for personnel, equipment, and material when raining.

- Understand and work as required in the safety procedure.

- Understand and follow strictly required steps in emergency case.

- Cooperate with expressway authority to keep safe for traffic, existing

constructions.

- Locate drill paths at site.

- Set up working base with support from general labor:

In flat ground: Earth work to excavate working trench.

In road shoulder: Foundation work to build up steel frame for drilling

equipment reinforcement.

- Arrange welding work to line up D200 galv. steel pipe before and during pipe

ramming work.

- Drill by using hdd machine to get the right path.

- Pipe ram to insert steel pipe into drilled hole to complete drilling work as

designed.

- Report to construction supervisor any difficulty when working, including:

ground condition, equipment condition, material/consumables condition,

traffic,… to prevent problem.

7. Equipment team

- Receive work order from construction supervisor.

- Daily check construction equipment for function.

- Prepare spare parts for maintenance or repair work.




- Cooperate with drilling team to mobilize / demobilize equipment, tools in the

safe way.

- Cooperate with drilling team to keep safe for equipment during work.

- Report to construction supervisor.

8. General labor

- Receive work order from drilling team.

- Understand and work as required in the safety procedure.

- Understand and follow strictly required steps in emergency case.

- Support for drilling team complete earth/foundation work.

- Support for drilling team to set up safety signs, safety fence, and protection.

- Support for welding work.

- Move tools, material to the right place as required by drilling team.

II.3. HORIZONTAL DIRECTIONAL DRILLING (HDD)

II.3.1. Pilot drilling

Pilot drilling is done by following the directional head from surface with the help of

the transmitter installed inside drill head. Signal from transmitter will be gained by a

receiver, which kept above by a technician and converted into drilling data in the

display. So the depth, direction and slope is known, in order to avoid existing

infrastructure.

Pilot drilling head can be changed according to the ground formation. Drilling is done

by rotation, directional drilling is done by head.




A remote display set up in drilling machine will show drilling data to help operator

knows about drill path.

The F Series™ Display (FSD™) lets you see drilling

information at the drill and can receive telemetry

signals from the F5®, F2

®, SE™, Eclipse

®, Mark III,

and Mark V locating systems. The FSD™ remote

display is equipped with externally mounted antenna.

Additional antenna options available upon request for

increased telemetry range.

II.3.2. Drill path and drilled hole size

Drill path must be controlled to keep followed designed, which is straight and parallel

with road surface at a depth of -2m min.

Drill head size is chosen with a considered drilling speed so that a D200 hole will be

created for next step. Drilled hole should be prepare for pipe ramming due to D200

steel pipe is quite small for keeping direction when ramming.




II.3.3. Drilling fluid

II.3.3.1. Drilling fluid function

Drilling fluid plays an important role in the success of drilling. Drilling fluid is a

mixture of water, bentonite, polymer and additives. Quantities of those elements will

be calculated basing on ground structure, pipe diameter, drill length.

A good drilling fluid will help to get the following:

- Transfer maximum cutting soil out of drilled hole.

- Create stable hole wall, avoid sand, gravel, stone,… collapse.

- Lubricate drilling tools or product pipe when moving.

II.3.3.2. Mixing procedure

Procedure for mixing is essential in the success of drilling. Well mixing will create a

good quality drilling fluid.

The following instruction from manufacturer must be followed:

- Quantity and adequate time for mixing bentonite.

- Quantity and adequate time for mixing polymer.

- Quantities of poured additives and mixing time.

- Mixing pumping speed, pressure.

For crossing No. 20 to No. 37, more additives shall be applied to overcome hard soil

condition with sticky clay and stone in various sizes.

II.3.3.3. Original

All bentonite, polymer, additives mobilized for drilling work will be U.S.A. original.

II.4. PIPE RAMMING

II.4.1. Setting up

Setting up the foundation and a frame for pipe ramming hammer is very important.

The right direction for hammer running will help to get D200 steel pipe reached at

destination without adjustment. The hammer will secured with D200 steel pipe and on

a guide rail, which runs together with hammer when working.




A trench will be dug in the equipment side for guide rail setting up.

In case of setting up in a road shoulder, a foundation with sand bag, steel frame will

be done so that rammer’s frame can run in a stable direction.

Another trench will be dug in the destination side to get D200 steel pipe end.

II.4.2. Pipe ramming technique

Refer links:

https://www.youtube.com/embed/WR-

CvMo2Rqg?rel=0&wmode=transparent

https://www.youtube.com/watch?v=hdc63KY9dyw

https://www.youtube.com/embed/WR-CvMo2Rqg?rel=0&wmode=transparent

https://www.youtube.com/embed/WR-CvMo2Rqg?rel=0&wmode=transparent

https://www.youtube.com/watch?v=hdc63KY9dyw







Flow diagram of ramming process

After pilot drilling D200 steel pipe will be inserted by pipe ramming technique.

Ramming accuracy is dependent on drilled hole. In case of only pipe ramming can

applied (where narrow space for drilling equipment setting up), drill path will be

reached by using laser pointer with a careful action.

When ramming, pushing force will be adjusted by control valves in the air compressor

so that the D200 pipe goes smoothly and soil out from pipe inside smoothly also. In

case of hitting to a hard object (stone, rock, hard soil structure), water jet will applied

to get the object loosen up for easier pipe running.




After complete pushing a pipe, a new pipe will be lined up and welded. When the

weld cooled down enough, rammer will lined up, secured and operated to continue

pushing.

A good ramming will be done with following a procedure, which carefully considered

basing on knowing ground structure. Drilling fluid kept inside drilled hole before

ramming will help to maintain D200 steel pipe direction and avoid wall collapse,

especially ramming through sand.

BH190 pneumatic pipe-ramming hammer

Pipe ramming hammer is a low frequency pneumatic impacting tool with large impact

power. It take compressed air as power source to drive cylinder punch hammer to beat

on hammering block, then the steel pipe directly rammer inside the stratum along the

rail track. When working, pipe ramming hammer produce larger impact force; this

force directly acts on the pipe end and passing through the pipe delivered to the front

pipe boots, cutting soil, the cut soil enter into the steel pipe, once pipes reach the

target pit, excluding the soil core, pipeline laying is completed.

Pipe ramming hammer is mainly used for steel pipe trenchless laying, also it can be

used for pipe shed construction, gold mining exploration, cast-in-place pile, steel pipe

pile and profiled steel sheet pile engineering and so on.

BH190 pneumatic pipe-rammer have very good application to the ground, easy

operating, suitable for small size pipe.

II.4.3. Main parts and functions of pipe ramming hammer system

II.4.3.1. Main parts

Pneumatic pipe-rammer is insist of pipe hammer, high pressure hose, oil injecting

system, lubricating system and other parts, the follow picture is the main structure.




1. Soil layer

2. Cutting heads

3. Steel pipe

4. Padding wood

5. Soil extractor

6. Soil extraction window

7. Pipe hammer

8. Pulley

9. Hooks

10. High pressure windpipe

11. Hammer-in valve

12. Oil injector

13. Oil level display window

14. Main air intake valve

15. Air compressor exhaust valve

16. Air compressor

17. Jet grouting steel pipe

18. Hammer pipe head

19. Pull ring

20. Jet grouting hose

21. Adjusting cone ringer

22. Tensioner

23. Jet grouting valve

24. Grout storage can

25. Pressure gauge

26. Intake air hose

27. Oil dose adjusting valve

28. Air intake valve of the jet grouting

pipe

29. High pressure hose.

II.4.3.2. Main functions

- The cutting head: also called pipe boots, welded in the front of steel pipes to

protect the pipe mouth, reducing the cutting area, compacting pipe outer soil

layer, reducing the soil layer friction on the steel pipe outer wall;

- Wood pad: adjusting steel pipe and pipe ramming hammer height to keep them

in the same axis;

- The soil excavating tool: transfer pipe ramming hammer impact force, discharge

out extrusive soil at the other end of the pipe which entering inside the steel pipe

during pipe ramming process.

- Pipe ramming hammer: providing pipe laying impact force;

- Inlet valve: used to start or shut off the rammer;

- Oiler: the compressed air brings the lubricating oil into the pipe ramming

hammer, to lubricate the moving parts in the pipe ramming hammers, injection

volume can be adjusted, and through oil window you can watch the inside oil

mass;




- Air compressor: providing compressed air to the rammer and sweep away soil

core of steel pipe;

- Pipe ramming head: preventing steel pipe month expanding or damage after

hammering;

- Adjusting taper sleeve: let the pipe ramming head, soil excavating tool and pipe

ramming hammers matching with steel pipe diameter;

- The grouting pipe: convey the mud or lubricating liquid to front end of the pipe,

rear channel of the pipe boot;

- Grouting system: consist of slurry storage tank, grouting pipe, air tube, control

valve, it can mud jack to the internal and external wall of steel pipe to reduce the

frictional resistance; in most cases the using effect of grouting system is not too

good because of grouting pipe breakage and lose efficacy, so it is not often used.

II.4.3.3. Soil cleaning

When the pipe going into the ground by impacting force, soil core enter in the steel

pipe, a soil cleaner powered by compressed air will be used for pushing out the soil

core inside pipes until ramming work is completed.

In hard ground conditions need high pressure water shall be used for soil cleaning.

1. Soil layer

2. Soil core

3. Steel pipe

4. Soil cleaning ball

5. Seal cover plate

6. Seal ring

7. Stop level

8. Air intake pipe

9- Air intake valve

10. Oil injector

11. Air compressor

Soil cleaner includes soil cleaning ball and seal cover plate. Outer wall of the soil

cleaning ball cling to the steel pipe wall, and thus it will form a piston in the steel

pipe, the effect of compressed air is making it go forward inside the steel pipe, then




the soil core inside the steel pipes will be pushed out from the steel pipe. The seal

cover plate is used for plugging the nozzle at the steel pipe end.

II.4.3.4. Pneumatic pipe rammer structure

1. Hammering block

2. Impact hammer

3. Cylinder

4. Air distributing hole

5. Air distributing rod

6. Damper

7. Hose

II.4.3.5. Pipe rammer selection

Correct selection of pipe ramming hammer is very important. Selection of pipe

ramming hammers basing on overall considering the traversing stratum, pipe laying

length and pipe diameter. Strata density, hardness, adhesion, water resistance, gravel

content,… has great influence on the rammer pipe laying ability.

It is relatively easily to laying pipes in soft, small viscous, rich water, less sand and

gravel content (less than 20%) stratum;

In the dense, hard, big viscosity, less water, large sand and gravel content (more than

60%) stratum laying pipe is relatively difficult.

In the actual engineering, you can choose the pipe ramming hammer with the standard

average pipe laying speed 2～5m/h.

Following chart gives a guidance for choosing hammer with standard ground

condition.




Hammer selection chart

II.4.3.6. Requirement for steel product pipe

II.4.3.6.1. Pipe outside cleaning

Steel pipe shall be clean and anti-corrosive, thus anti-corrosion work must be done

before construction. The best method is covering the pipe with glass fiber, other

methods can be applied are: asphalt covering, epoxy covering, painting.

II.4.3.6.2. Wall thickness

Strong enough pipe wall helps to keep stable for pipeline during ramming so that pipe

can reach at desired destination. When wall thickness is less than the required,

additional reinforcement must be applied to pipe end and seam welding joint, in order

to prevent the steel pipe end part and the seaming place to be cracked.

pipe diameter wall thickness pipe diameter wall thickness

≤Φ100mm 4mm Φ500—Φ800mm 9mm

Φ100—Φ180mm 5mm Φ800—Φ1000mm 10mm




Φ180—Φ250mm 6mm Φ1000—Φ1200mm 12mm

Φ250—Φ350mm 7mm Φ1200—Φ1500mm 15mm

Φ350—Φ500mm 8mm Φ1500—Φ2000mm 19mm

Requirement for wall thickness

II.5. EARTH/FOUNDATION WORK FOR DRILLING EQUIPMENT

II.5.1. Earth work in flat ground

Earth work to make working trench for guide rail, hammer setting up in flat ground.

After digging trench, protection work will be done, such as: cover arrangement, water

pump arrangement,

II.5.2. Earth/foundation work in road shoulder

In case of arranging drilling equipment in road shoulder, earth work and foundation

work shall be done to get a stable working base.

Earth work includes following steps:

- Clean up ground from water, rubbish, trees,…

- Level up by sand bags, soil to desired level so that can get drill path -2m from

road surface.

Foundation work includes following steps:




- Pile up by wooden piles so that a secured frame can be made to protect sand

bags, soil from collapse, especially in raining time.

- Steel work to make a strong frame for drilling machine’s working base. Frame

shall be made by welding or joining up by bolts and nuts depending on safety

requirements.

- Secure drilling machine into steel frame.

- Secure rammer’s frame into steel frame after drilling work.

Drilling equipment reinforcement help to keep machine stable so that desired drill

path can be done in 1 time pilot drilling without interruption for adjustment.

Good reinforcement also help to protect machine from slipping or falling down from

working base.

Earth/foundation work shall be done before mobilization, avoiding wasting time for

waiting.

II.6. OVERCOMING ACTIONS WHEN DRILLING/RAMMING PROBLEM

When drill head hit a hard object, the following steps must be done:

- Check back ground structure reports to estimate object with type, size.

- Try to go through the object place, if can.

- Calculate a substituted action.

- Take back drill head and change direction without moving drilling machine.

- Move drilling machine to more suitable place and start a new drilling.

- Report to Employer/Contractor.

When rammed pipe hit a hard object, the following steps must be done:

- Check back ground structure reports or drilling report to estimate object with

type, size.

- Try to go through the object place, if can.

- Take back pipe and try another ramming.

- Move pipe and hammer more suitable place and start a new drilling.

- Report to Employer/Contractor.




CHAPTER III

WORK PLAN

III.1. SUGGESTED ACTIVITIES

1. Crossing No.1 Km0+100, Pk4-ITS008-G-111-D: 44m

Site condition Suggested activities

1. Site entrance: in ramp way.

- Mobilization done at night time to avoid

traffic problem.

- Safety signs, fence, barricade will be set

up.

2. Mobilization space: wide enough

but in grass area. - Keep tidy for grass area.

3. Ground structure: fill-in soil with

sand, fine gravel. Technique: drilling.

4. Ground level: lower than around,

will be filled with water in raining

time

- Foundation work done to keep equipment

laying on higher level to keep away water

when raining.








traffic problem.


up.







time



when raining.






1. Site entrance: in expressway.


traffic problem.


up.

2. Mobilization space: narrow. - Earth work done to extend work space.


sand, fine gravel. Technique: pipe ramming.

4. Ground level: not high, will be

filled with water in raining time

- Pump trench water out at all time.

- Cover work space when raining.








traffic problem.


up.



sand, fine gravel. Technique: drilling and pipe ramming.










1. Site entrance: in residential way. - Safety signs, fence, barricade will be set

up.



sand, fine gravel. Technique: pipe ramming.











- Mobilization done in off-peak time to

avoid traffic problem.

- Safety signs, fence, barricade shall be set

up.

2. Mobilization space: narrow.

- Foundation work done to extend work

space.

- D200 pipe must be cut short when doing

pipe ramming.



4. Ground level: far lower than road

surface.

- Set up strong steel frame at road shoulder

at level of -2m from road surface for

drilling activities










up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.
















up.



space.


pipe ramming.
















up.



space.


pipe ramming.














traffic problem.


up.







time



when raining.








traffic problem.


up.


but in road area. - Keep tidy for road area.





time



when raining.




14. Crossing No.14 Km23+330, Pk4-ITS008-G-224-D (1): 60m




traffic problem.


up.







time



when raining.








traffic problem.


up.







time



when raining.










up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.




surface.



drilling activities










up.


- Earth work done to extend work space.


pipe ramming.
















up.




pipe ramming.




filled with water in raining time.












up.




pipe ramming.

3. Ground structure: Hard soil with

stone in various sizes Technique: pipe ramming.





5. Adjacent constructions: Concrete

drainage trench crossing working

area at 3m away from express way

fence, closed to sloping ground

Working trench will be dug crossing and

under existing trench to 4m, enough for

ramming.










up.




pipe ramming.











- Working trench will be dug crossing and


ramming.

- Excavator shall be used when hand

digging is impossible.










up.




pipe ramming.













ramming.












up.




pipe ramming.













ramming.












up.




pipe ramming.













ramming.












up.




pipe ramming.













ramming.












up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.


stone in various sizes. Technique: drilling and pipe ramming.


surface.



drilling activities










up.




pipe ramming.













ramming.












up.




pipe ramming.













ramming.












up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.




surface.



drilling activities










up.



space.


pipe ramming.




surface.



drilling activities










up.




pipe ramming.


stone in various sizes Technique: drilling and pipe ramming.








fence.



ramming.












up.




pipe ramming.










fence.



ramming.












up.




pipe ramming.










fence.



ramming.






III.2. WORK PLAN

Project work plan consists of plans for 37 crossings, which calculated from work steps

in each crossing and general preparation, final check, hand over time.

Work steps generally described in table 5 – Plan for a crossing with estimated

construction time basing on:

- Site condition, including: entrance, mobilization space, ground structure,

ground level, adjacent constructions,…

- Expressway regulations.

See table 6 – Project general plan for the whole project estimated time table, which

prepared for 2 teams working concurrently and closely to each other.

METHOD STATEMENT – D200 EXPRESSWAY CROSSING BY HDD AND PIPE RAMMING TECHNIQUE


Table 5 – Plan for a crossing

No. Responsibility

Activities

Drawing

/Document Manpower

Equipment

/Tools to be

used

Time

(estimated) Safety Report

I PREPARATION

Action: Deltatech

* Work

permit

* Approved

drawings

* Approved

procedures

/regulations

from

Employer

/Contractor

Site Manager

Safety

supervisor

Logistic/Ad.

Construction

supervisor

Drilling team

Equip. team

General Labor

7-seat car

15 ton cargo

crane

2-3 days

* Set up safety signs,

fence, barricade,

personnel equipped

with PPE.

* Safety meeting

before work.

* Keep safe distance

from dangerous

objects.

* Work under safety

supervision

*Daily

work.

report.

*Safety

reports.

Supervision:

Employer/Contractor

II DRILLING/RAMMING WORK

Action: Deltatech

* Work

permit

* Approved

drawings

* Approved

procedures

/regulations

from

Employer

/Contractor

Site Manager

Safety

supervisor

Logistic/Ad.

Construction

supervisor

Drilling team

Equip. team

General Labor

D24x26 drilling

machine

Digitrak F5

locator

Bentonite

mixing tank

BH190

ramming

hammer

Welding

machine

2 days for

drilling / 2

days for

ramming


fence, barricade,

personnel equipped

with PPE.

* Safety meeting

before work.


from dangerous

objects.

* Work under safety

supervision.

*Daily

report.

*Safety

reports.

*Drilling

/ramming

reports.

Supervision:

Employer/Contractor

1. Set up mobile accommodation

camp.

2. Locate drill path at site.

3. Earth/foundation work.

4. Mobilize equipment, tools,

material, consumables

5. Pilot drilling.

6. D200 pipe ramming.

7. Welding work to join up pipes

until complete ramming.

8. Cleaning up pipe inside.



III FINAL CHECK, HAND OVER, DEMOBILIZATION

Action: Deltatech

* Work

permit

* Approved

drawings

* Approved

procedures

/regulations

from

Employer

/Contractor

Site Manager

Safety

supervisor

Logistic/Ad.

Construction

supervisor

Drilling team

Equip. team

General Labor

7-seat car

15 ton cargo

crane

1 day


fence, barricade,

personnel equipped

with PPE.

* Safety meeting

before work.


from dangerous

objects.

* Work under safety

supervision.

*Daily

report.

*Drilling

/ramming

reports.

*As-built

documen

ts.

*Hand-

over

documen

ts.

Supervision:

Employer/Contractor

`

9. Final check, including: data

check, take measure.

10. Hand over.

11.Take a part structures for

demobilization.

12. Reinstatement.

13. Demobilization.



Table 6 – Project general plan

Item Steps of work Time (week)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

I General preparation

II Construction

1 Crossing No.1

2 Crossing No.2

3 Crossing No.3

4 Crossing No.4

5 Crossing No.5

6 Crossing No.6

7 Crossing No.7

8 Crossing No.8

9 Crossing No.9

10 Crossing No.10

11 Crossing No.11

12 Crossing No.12

13 Crossing No.13

14 Crossing No.14

15 Crossing No.15

16 Crossing No.16

17 Crossing No.17

18 Crossing No.18

19 Crossing No.19

20 Crossing No.20

21 Crossing No.21



22 Crossing No.22

23 Crossing No.23

24 Crossing No.24

25 Crossing No.25

26 Crossing No.26

27 Crossing No.27

28 Crossing No.28

29 Crossing No.29

30 Crossing No.30

31 Crossing No.31

32 Crossing No.32

33 Crossing No.33

34 Crossing No.34

35 Crossing No.35

36 Crossing No.36

37 Crossing No.37

III FINAL CHECK, HAND

OVER, DEMOBILIZATION



CHAPTER IV

SAFETY CONTROL

All the factors in construction activities must be checked for safety carefully before and

during work. Checking is to find out inadequate matters, potential risks for preventive

actions or repair.

Checking procedure shall be done in various ways:

- Daily checking: For any working activity.

- Before work checking: For new construction site.

- Unexpectedly checking: In case of high risk.

IV.1. Personnel check

IV.1.1. Personality check

- Check personal training certificates.

- Check for safety training certificates.

- Check for heath certificates.

IV.1.2. Protection check

- Check PPE before and during start work.

- Check for understanding safety requirements.

- Check for working regulation obeying during work.

IV.2. Working base check

IV.2.1. Working trench check

- Check for tidiness. Trench must be free of water, mud.

- Check for protection arrangement, especially in raining time.

- Check for working space.

- Check for mobilization way.

- Check for way out in emergency case.

IV.2.2. Foundation check

- Check for tidiness. Foundation must be free of water, mud.

- Check for secure system. All parts in foundation must be secured each

other strong enough.

- Check for protection arrangement, especially in raining time.



- Check for working space.

- Check for mobilization way.

- Check for way out in emergency case.

IV.3. Equipment/tools check

IV.3.1. Function check

Start up machine and check for working condition.

- Try all functions, one by one.

- Listen for strange noise.

- Check gauges for accuracy.

- Check electric system for function by using electric meter.


- Check for grounding system.

- Check for pressurized oil leaking.

- Check for pressurized air leaking.

- Check for electric leaking.

- Check for potential crack, disconnect, wrong function.

IV.4. Material/consumables check


- Check for failures can cause crack, break in material during work.

IV.5. RISK ASSESSMENT

Before work, a risk assessment shall be conducted and explained in details in safety

training, toolbox meeting. Site manager and safety supervisor are responsible for risk

assessment.

1. Work in and across expressway

- Activities:

o When mobilization, transportation vehicles stay near expressway safety

fence and off load equipment/tools, material.

o During work, workers move tools, material across expressway.

- Potential danger: traffic problem

o Car hit.

o Slip when moving objects in expressway.

o Traffic jam.



2. Work with drilling machine

- Activities:

o When drilling, drill rods and its carrier moving forward/backward,

rotating by operator’s actions.

o When feeding rod, workers take a rod in by hand.

o Working with hydraulic system in drilling machine.

o When drilling machine working on foundation vibrating force makes

machine moving.

- Potential danger: operation problem

o Moving object hit to worker.

o Possibly pressurized hydraulic oil leaking causes working people

injured.

o Falling down of drilling machine, especially in wet condition after

raining.

3. Work with pipe ramming hammer

- Activities:

o When ramming, the hammer moves forward by pressurized air.

o When feeding pipe, workers take a pipe in by hand for welding.

o When continue ramming, workers take hammer in and line up with pipe

by crane and hand.


o Hammer slip away from frame.

o Falling down of hammer or guide rail, especially in wet condition after

raining.

o Air compressor line out failure causes people injured.

4. Work with electric devices (generator, welding machine, grinding machine,…)

- Activities:

o When ramming, the rammer moves forward by pressurized air.

o When feeding pipe, workers take a pipe in by hand for welding.

o When continue ramming, workers take rammer in and line up with pipe

by crane and hand.


o Rammer slip away from frame.



o Falling down of rammer or frame, especially in wet condition after

raining.

o Air compressor line out failure causes people injured.

IV.5. SET UP AND MAINTAIN SAFETY

1. Set up safety signs, fence, barricade.

2. Equip PPE for working personnel.

3. Safety training, daily toolbox meeting done to ensure that all working personnel

understand how to work in safely way.

4. Set up protection method for adjacent constructions, especially for underground

constructions. Stop working when protection method is violated.

5. Ground survey in important places to find out potential risks.

6. Ensure that all working activities done as required in work permit.

7. Start work when all safety method set up already.

8. Site manager is highest responsible for safety in any working activities.

9. Safety supervisor stays at site at all working time, stop unsafe activity and report

to site manager for re-organizing construction work.



CHAPTER V

QUALITY CONTROL

Construction quality will be achieved when the processes: making product pipeline, pilot

drilling, pipe ramming are controlled.

The whole quality control consists of following steps:

- Document control.

- Material/consumable control.

- Equipment/tools control.

- Drilling/ramming technique control.

- Welding test.

V.1. Document control

All construction activities shall be documented by construction supervisor so that

management personnel can check and for adequately.

Site manager will check those regularly:

- Check certificates for properly.

- Check data reports to make sure that drill path done as required, especially

the drill depth.

- Check daily report for working progress, schedule, problem,… to manage

work done as required.

V.2. Material/consumables control

Construction supervisor shall check all activities relating to material/consumables:

- Storage.

- Heat treatment for welding consumable.

- Mixing process for drilling fluid.

- Failures happened during work.

- Substitution, if any.

V.3. Equipment/tools control

Construction supervisor shall check and make sure equipment/tools can work without

unexpected problem. Stop work and report to site manager in case of wrong function.



V.4. Drilling/ramming control

Construction supervisor shall check operators for working procedures and make sure that

drill path, ramming work will be done as required. Stop work and report to site manager

in case of inadequately.

V.5. Welding work control

Construction supervisor shall check welder for operation and make sure that the weld

will be done as required. Stop work and report to site manager in case of inadequately.

- Visual check for all weld, take measure to control weld dimensions.

- Random test when required by penetration test (PT) method.

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Documents

Method Statement - D200 Expressway Crossing by HDD and Pipe Ramming - English