4

2
!
.
3
!
#
4
)
/
.
3

0
!
0
%
2
4UNNELLINGAND0IPEJACKING4ECHNIQUESFOR
4RENCHLESS)NSTALLATIONOF$RAINAGE0IPELINES
long Kong. u c/ty on h///y nuturu/ tcrru/n. w/th u totu/ urcu oj 1.000 squurc k//omctrcs. hus
u ou/ut/on oj 7 m////on. lts Jcvc/omcnts mu/n/y conccntrutc /n 20% oj thc ut /unJ /n thc
coustu/ urcu. most/y jormcJ by rcc/umut/on jrom thc scu. Thc ru/J cconom/c growth /n thc /ust
20 ycurs JcmunJs ncw /njrustructurc unJ ugruJ/ng oj cx/st/ng juc///t/cs. Thc crowJcJ sughctt/
//kc com/cx oj cx/st/ng ut///t/cs unJ scrv/ccs unJcrgrounJ /n thc //m/tcJ rouJ succ. unJ thc
busy trujc. mukc such ugruJ/ng unJ construct/on oj ncw jcuturcs. by thc convcnt/onu/ ocn
trcnch mcthoJ. J/jcu/t. Thc usc oj tunnc///ng unJ /cjuck/ng tcchn/qucs cou/J howcvcr rcso/vc
most oj thc rob/cms ussoc/utcJ thcrcw/th. such us J/sturbuncc to trujc. mujor J/vcrs/ons oj
cx/st/ng ut///t/cs. curth mov/ng. unJ cjjcct oj /nc/cmcnt wcuthcr. Th/s wou/J u/so m/n/m/sc ub//c
com/u/nts Juc to /nconvcn/cncc unJ /oss oj bus/ncss /n thc ncurby shos us tcmorury trujc
munugcmcnt schcmcs urc on/y rcqu/rcJ ut thc juck/ng unJ rccc/v/ng shujt /ocut/ons. Th/s ucr
J/scusscs thc vur/ous tycs oj tunnc///ng unJ /cjuck/ng tcchn/qucs uJotcJ /n long Kong
jor Jru/nugc /c//nc construct/on unJcr J/jjcrcnt s/tc constru/nts unJ grounJ conJ/t/ons. thc/r
crjormuncc. thc rob/cms cncountcrcJ unJ thc rccommcnJut/ons muJc.
+EYWORDS 5hujt Construct/on. lunJJug Tunnc/s. lcuJ/ng Construct/on. Furth Prcssurc
3u/uncc McthoJ. 5/urry Prcssurc 3u/uncc McthoJ. Tunnc/ 3or/ng Much/nc.
CrounJ 5ctt/cmcnt. Contro/ oj Tunnc/ 4//gnmcnt. Rcscuc Dcrut/on
WiIson W S MOK
Vc|n|orJ| (C8S| /|J
K W MAK
Dro|nogc Scrv|cc: Dcor|mcn|
Covcrnmcn| oj ||c //S4
Thc long Kong lnst/tut/on oj Fng/nccrs Trunsuct/ons. vo/ 16. No 2. 1627
Introduction
The roads in the urban areas of Hong Kong are generally congested with
underground utilities and services of different types and sizes, at different
depths. To meet the development demand, new features are constantly
added and existing installations are upgraded over the years. This forms
a spaghettilike complex network, causing problem to accommodate more
new installations due to lack of suffcient space. Diversion of existing
utilities and services to give room for such installations is diffcult as other
locations in the vicinity may also be crowded with utilities and services. ln
the past, the installations were commonly carried out by the conventional
opentrench method, requiring the implementation of temporary traffc
management schemes (TTMSs. These TTMSs are usually limited to no
more than 20 30 m in length in each stage, depending on whether
existing buildings are located ad|acent to the works site, due to the
requirement of allowing space for access of fre engines under emergency
situations, and other factors, such as access to shops or premises. This
limited length of TTMSs could only allow limited utility diversion, and
therefore may not effectively resolve the problem. At some locations,
the underground is congested with existing utilities and services in
layers, rendering such new lnstallations by the conventional opentrench
method impossible. Tunnelling and pipe|acking can however minimise
such effects as road openings are only restricted to the shaft locations,
ie |acking shaft and receiving shaft between a pipeline, which can be
selected to avoid conficting with traffc and ma|or utilities or minimise
their diversions. Sometimes, tunnelling and pipe|acking techniques are
adopted solely to minimise traffc disruption, in extremely busy areas,
or in response to public requests or complaints on the same concern,
or even to avoid the felling of valuable trees.
Pipe|acking is a technique of pipeline installation, by hydraulically pushing
a pipe string, effected either mechanically by a tunnel boring machine
(T8M or manually for excavation, from a |acking shaft to a receiving
shaft. Jacking pipes are then added one after another to the end of the
pipe string as the preceding pipe/ T8M advances. The excavated materials
are then transported to the |acking shaft through a trolley system, for
handdug tunnels and earth pressure balance (EP8 T8Ms, and then
lifted up to ground surface, or by a slurry discharge pipeline for slurry
operated T8Ms. This procedure is repeated until the pipe string reaches
the receiving shaft |1|.
The history of using pipe|acking techniques for constructing drainage
pipelines in Hong Kong is short, with the track record in 1989 that
370 m of sewers, in diameter of 1,350 mm, located 6 14 m below
ground, were constructed by T8Ms under 5 drives, with a length ranging
from 40 to 80 m, passing beneath ma|or roads |2|. Since then, the scale
of pipe|acking works has increased signifcantly, with the deployment of
different types of T8Ms operating in different modes, to account for the
ground conditions likely to be encountered, and also the introduction
of handdug tunnels for constructing pipelines crossing old seawalls and
congested utility zones, or ground susceptible to artifcial obstructions.
ln some pro|ects, some of the works by opentrench may need to be
changed to tunnelling and pipe|acking techniques during the construction
stage, to suit constraints of traffc and existing utilities, and such is usually
carried out by means of heading construction due to its simple setup
and fast operation. Up to 2002, more than 14 km long pipelines, with
a diameter range of about 450 3,000 mm, using such techniques,
have been completed by the Drainage Services Department (DSD of
the Covernment of the HKSAR |3|.
8etween 1996 and 2006, some of the notable pro|ects employing
tunnelling and pipe|acking techniques were the West Kowloon Reclamation
Hinterland Drainage Package 2 (Northern Portion (with a length of more
than 1 km, the Central, Western and Wan Chai West Trunk Sewers (with
a length of 6 km, the Aberdeen, Ap Lei Chau and Pok Fu Lam Sewerage
Stage 18 (with a length of 2 km, and the Wan Chai East and North
Point Sewerage Trunk Sewers (with a length of 4 km, under different
geological conditions and depths.
The Wan Chai East and North Point Sewerage Trunk Sewers was the frst
DSD pro|ect using slurry operated T8Ms to construct curved sewers with
a minimum radius of 320 m, and a Sshape sewer (404 m long, with a
combination of straight and two curved sections (of radius 500 m and
passing through an intermediate shaft and launching into the receiving
shaft, both with the completion of the permanent shaft in advance |4|.
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
16
Some other pro|ects also use pipe|acking or heading techniques but in
a much smaller scale.
CeoIogicaI Conditions
The geological conditions in Hong Kong soils are highly variable in a
short length. The narrow strip of land along the seafront, ad|acent to very
steep slopes, has been formed by cut and fll techniques in the terrain
over the years, and generally consists of a thin layer of fll underlain
by colluvium and completely to highly weathered granite near the hills
to a thick layer of fll, with different contents of boulders at different
depths, overlying marine deposits, alluvium and completely to highly
weathered granite towards the sea. Depth to bedrock ranges from 1 to
2 m to 10 to 30 m below ground in a downslope direction. There is a
wide range in particle size between materials in different areas. Very
large boulders or corestones could exist at high levels of the ground.
Metallic ob|ects, anchors and cannons may also be expected in the old
flling areas and in marine deposits.
Croundwater levels tend to be high, generally 2.5 to 3.5 m below ground
level, and tidal response affects much of the urban area.
Shaft Construction
ln urban areas, due to constraints of traffc and existing utilities, some of
the |acking and receiving shafts have to be constructed at side streets.
They are generally constructed by sheetpiles in homogeneous clayey
to sandy ground (Fig 1 and pipepiles in mixed ground conditions
(Fig 2. Vibration and settlement monitoring are carried out during the
piling operation to avoid causing damage to ad|acent utilities, services,
roads and structures. More expensive pipepiles are sometimes used in
hard ground to minimise noise and vibration. For sheetpiles, to minimise
vibration, boulder obstructions at intermediate depths are prebored
before commencement of pile driving. At some locations, due to the
presence of hard materials at different depths, it would be diffcult to
maintain the verticality of the sheetpiles during driving, and the toe
of the sheetpiles would easily be damaged, causing the problem of
interlocking with ad|acent piles, often with insuffcient embedment length,
and necessitating toe grouting as a remedial measure.
Rectangular shaft is usually constructed because it is more easily to
be modifed to accommodate existing utilities and services. However,
at locations where these features are absent, circular shaft is used due
to the smaller member size of temporary works required. For a 1,800
mm diameter T8M, the typical size of a shaft is generally 8 m x 8 m
or 8 m in diameter. This generally would necessitate the occupation of
more than two traffc lanes. As such, the construction has to be carried
out in stages, with one portion completed and deckedover before the
commencement of another, such that disruption to traffc could be
minimised. At traffc sensitive locations, the receiving shaft could be
temporarily decked over after construction and reopened to allow traffc
fow until the pipe|acking drive is completed and the T8M can be lifted
up to ground surface during traffc nonpeak hours.
ln areas of congested utilities and services, it is usually diffcult, if not
impossible, to have a clear shaft, by virtue of the long time required
for utilities diversion and the limited space. Therefore, unless they
obstruct the pipe|acking operation such as lowering of T8M/ |acking
pipes or removal of excavated material, these utilities and services are
temporarily supported inside the shaft, by steel frames. This, however,
would create windows in the temporary works, entailing the erection of
steel lagging plates as support and to prevent ingress of groundwater
(Fig 3. Sometimes, the shape and size of a shaft need to be tailormade
to suit utility constraint, resulting in the use of a combination of sheetpiles
and pipepiles to overcome the problem. ln some cases, raking piles
F/gurc 2 ~ Tcmorury 5hujt FormcJ by P/c//cs
F/gurc 1 ~ Tcmorury 5hujt FormcJ by 5hcct//cs
F/gurc J ~ 5tcc/ lugg/ng P/utcs Prov/JcJ /n thc W/nJow oj Tcmorury
Works
have to be constructed to avoid interference with existing utilities and
services. The use of a concrete wall cast against the pipepiles is always
required to ensure the stability of the shaft if watermains or drainage
pipelines are in their close proximity as their bursting/ breakage could
signifcantly disturb the ground.
For deep shaft, grouting is always required in the perimeter to ensure
watertightness, before excavation is to commence. After the shaft has been
formed, a thrust wall and a launching/ receiving eye are then constructed
to allow the pipe|acking operation. For multidirection driving, a circular
thrust wall can provide better orientation and transfer of loading.
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
17
2 bars is required to balance the water head in the excavation face and
be maintained inside the tunnel round the clock to avoid fooding which
may in turn affect tunnel stability. To ensure constant supply of air, a
standby compressor is provided for emergency situations. Pressurisation
and depressurisation is required in the airlock installed on top of an air
deck erected in the |acking shaft, for personnel entering and leaving the
tunnel respectively. A medical lock needs to be provided at the shaft
location when the applied compressedair pressure exceeds 1 bar. There
have been some cases that air was found leaking through the porous
ground during tunnel excavation, resulting in infow of groundwater. This
entailed horizontal grouting from inside the handshield to stabilise the
ground before further excavation could be proceeded with.
The rate of excavation is generally 1 2 m per day for freeair tunnel
and 0.5 1 m per day for compressedair tunnel, depending on the
ground conditions.
Heading Construction
Heading construction is a simple form of handdug tunnel, and is widely
used to construct short pipelines, usually in the range of 10 30 m
in length, crossing road |unctions or locations of congested existing
utilities and services, in shallow depth, due to its easy setup and thus
the relatively low cost. The tunnel size could generally vary from 1.5
to 2.5 m in diameter, depending on the size of pipeline to be installed.
To tackle different site constraints and ground conditions, the method
of construction in each tunnel could vary, and the following cases are
typical examples.
To suit the limited space in the |acking shaft which is a common
phenomenon in urban areas as constrained by existing utilities, the shield
head can be tailormade by several short sections and connected together
Depending on the size and depth of the shaft, and the ground conditions
encountered, each shallow shaft (less than 8 m in depth generally
requires 6 to 8 weeks for completion from piling to excavation. The
construction for deep shaft (up to a depth of 22 m would however take
a longer time, from 12 to 18 weeks, due to the high variation in ground
conditions, particularly the rock content.
These shafts are later used for construction of permanent shafts for future
maintenance. As most of the shaft locations have different degree of
utility constraints, the location, size and shape of access and desilting
openings of each permanent shaft may need to be tailormade to suit
the site condition.
Modes of TunneIIing Operations
Three modes of operations are commonly adopted for pipe|acking
works in Hong Kong. They are handdug tunnel, earth pressure balance
T8M and slurry pressure balance T8M. The contractor will, based on
the results of site investigation conducted in the design stage by the
client, assess the risk and carry out further investigation if doubt exists
and select the most appropriate mode for the ground conditions likely
to be encountered.
Hand-dug TunneI
Handdug tunnel, formed by precast reinforced concrete segments as
temporary lining and connected each other with a bolting system and a
rubber gasket at the |oint to prevent ingress of water, can be constructed
under either a freeair or a compressedair environment.
Freeair tunnel (Figs 4 and 5 is suitable for shallow pipelines crossing old
seawalls, artifcial obstructions and road |unctions, usually less than 50 m
in length for a drive. Prior to tunnelling, the alignment of the pipeline is
fully stabilised by grouting to ensure stability. The excavation is effected
manually by pneumatic tools or mechanically by a mini backhoe inside
the handshield (ie a protective tube in front of the pipeline to allow
manual excavation by workers, if the diameter of the tunnel permits
(usually 1,800 mm or above. The excavated materials are transported
to the |acking shaft by a trolley system and then lifted up to ground
surface. The handshield is advanced by extending the hydraulic |acks
installed with it, against the concrete segments erected at the rear as
reaction. New segments are then added after the retraction of hydraulic
|acks. The overcut between the ground and the segments is immediately
flled up with grout to prevent settlement. This procedure is repeated until
the tunnel reaches the receiving shaft. Upon completion of the tunnel
construction, a permanent pipeline is pushed inside from the |acking
shaft and its annulus is flled up with grouting materials equivalent to
the strength of the overlying ground.
Compressedair tunnel (Figs 6 to 8 is applicable to grounds where
groundwater table is high. Depending on depth, an air pressure of 1 to
F/gurc 4 ~ luunch/ng oj lunJ 5h/c/J jor Frcc 4/r lunJJug Tunnc/
F/gurc 5 ~ Fxcuvut/on /n Frcc 4/r lunJJug Tunnc/
F/gurc 6 ~ Ccncru/ v/cw oj ComrcsscJ 4/r 5ctu /n !uck/ng 5hujt
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
1
one by one by welding inside the |acking shaft before launching. This
is then followed by steel sleeve pipes or precast concrete pipes which
are pushed forward into ground by a hydraulic system in the |acking
shaft (Fig 9, with lubricant constantly in|ected under a pressure slightly
higher than the overburden pressure, from the grout holes installed in
the pipes to minimise soil friction, and to avoid closeup of the overcut,
causing ground settlement, during the |acking operation.
To determine the ground condition, probing is carried out in every
2 3 m ahead of excavation. The ingress of water, if any, is controlled
by the in|ection of grout, by means of horizontal and inclined holes
from the shield head, prior to excavation. lf instability is found in the
working face, steel shutter, in the form of plankings, needs to be erected
at the front of the shield (Fig 10, and the working personnel evacuated
until the ground treatment is completed, by specialised working gangs,
After pushing the sleeve pipeline into the receiving shaft, the annulus,
formed by overcut, is flled up with grout, with a strength equivalent to
the overburden pressure, to avoid ground settlement.
At narrow shaft locations where lowering the sleeve pipes is a problem,
the tunnel lining could be formed by steel segments connected to each
other by welding (Fig 11.
The advancement of the shield head is effected by extending the hydraulic
|acks installed with it against the steel segments erected at its rear
(Fig 12. The overcut outside the segments is immediately flled up by
grout, through the holes provided at the crown and the axis at the two
sides, after the completion of each ring in the tunnel. This method is
generally applicable to the construction of small size of pipelines.
For crossing ma|or roads where underground boulder obstructions are
expected, the temporary works in the tunnel, formed by drilling horizontal
pipepiles from one shaft to another, could effectively penetrate through
such obstructions to act as temporary lining (Fig 13, thus ensuring the
stability during excavation. Depending on ground and groundwater
F/gurc 7 ~ Fxcuvut/on /n ComrcsscJ 4/r lunJJug Tunnc/
F/gurc 9 ~ !uck/ng oj 5tcc/ 5/ccvc P/c jor lcuJ/ng Construct/on
F/gurc 8 ~ Ccncru/ v/cw oj u Com/ctcJ Tunnc/
F/gurc 11 ~ 4curuncc oj u Tunnc/ FormcJ by 5tcc/ 5cgmcnts
F/gurc 10 ~ 5tcc/ P/unk/ng FrcctcJ /n Fxcuvut/on Fucc to Prcvcnt lngrcss
oj CrounJwutcr
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
19
conditions, grouting may be required to stabilise the ground by in|ection,
through the slot holes provided in the pipepiles, before excavation
takes places. The permanent pipeline is then pushed into the tunnel
after excavation (Fig 14, and its annulus is flled up with lean concrete
or grouting materials, as appropriate. This method is usually suitable for
constructing relatively large size of pipeline in deeper ground.
For tunnelling in flling ground with low rock content in shallow depth,
the temporary works could be in the form of a portal frame, constructed
by driving several short sections of steel plankings or channels, in the
direction of excavation, ahead of excavation, and then supporting them
by steel members after excavation (Fig 15. This method is however
unsuitable for water bearing ground due to the presence of gaps between
the plankings/ channels that the ingress of water could pose stability
problem in the tunnel, particularly during dewatering.
The average production rate for heading construction is generally
1 2 m per day. lf large boulders or fullface rock are encountered in the
excavation face, their removal has to be carried out by pneumatic tools
as the size of the tunnel does not allow the use of heavy mechanical
plant. Hence, the rate of progress is generally slow, with 100 200 mm
in length achieved per day. ln addition, maintaining stability of overlying
ground during boulder removal is always a problem.
The heading construction method also enables the alignment of a tunnel
to be ad|usted, by lowering or shifting the shield head/ segments to
either side, to avoid conficting with unexpected utilities or services
encountered during excavation, thus giving more fexibility to resolving
the problem, when compared with the T8M tunnelling.
Heading construction, by means of steel plankings and portal frames,
has become popular in Hong Kong recently, particularly for installing
branch sewers or drains where groundwater is usually not a problem.
This is due to its easy setup, not requiring heavy machinery, and its
fexibility in handling obstructions. The downside of this method is that
construction may be dangerous if the soil cover is too shallow. lts left
in temporary works also takes up an underground space, flled with
steel sections, much larger than the pipes to be laid, typically 1.5 m x
1.5 m, to enable manual operation, thereby making the already congested
underground space even more so and also imposing diffculties for future
maintenance of the laid pipes.

Earth Pressure BaIance Method
Earth pressure balance T8M (Figs 16 to 18 is adopted for tunnelling
through homogeneous ground made of clay, silt or sand, usually in the
layers of fll, marine deposits and alluvium. The cutting wheel generally
appears in spoke type, with tungsten carbide cutting bits mounted on
the surface and a screw crusher in the center. lt is capable of excavating
soft rocks of sizes up to 25 of the area of the cutting wheel.
The system works on the principle of maintaining pressure in the
excavation chamber equal to the hydrostatic pressure in surrounding
ground. This pressure is constantly monitored and controlled by varying
the speed of the screw conveyor. The excavated materials are transported
to the |acking shaft, by a trolley system, and then lifted up to ground
surface. When soft ground is encountered or excavation is carried out
F/gurc 1J ~ Tunnc/ FormcJ by lor/zontu/ P/c//cs
F/gurc 15 ~ lunJJug Tunnc/ ConstructcJ by 5tcc/ P/unk/ngs w/th Portu/
Frumcs
F/gurc 12 ~ Fxtcns/on oj lyJruu//c !ucks /n lcuJ P/c jor 4Jvunccmcnt F/gurc 14 ~ Pcrmuncnt P/c//nc lnstu//cJ /n thc Tunnc/
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
2
below groundwater, high water absorbent polymer or other conditioning
agents are added to the excavation chamber frmly grabbing the soil to
stabilise the excavation face and to ease the mucking process.
For |acking shaft, the works area required is less than that of the slurry
pressure balance method, due to less plant required for the operation,
and could vary from 3.5 to 5 m in width (ie the width of the shaft and
be generally in the range of 20 30 m in length. At locations where
space is a problem, the size of the works area could be reduced by
stacking some of the plant. For receiving shaft, the works area is much
smaller and is only required when the T8M is lifted up from the shaft
after completion of the pipe|acking works.
Common sizes of T8Ms range from 1,050 mm to 1,800 mm, but the
use of 2,600 mm diameter T8Ms has been experienced. Due to their
simple confguration, in particular only cutting bits are equipped in the
cutting wheel and no telescopic section is provided at the rear of the
T8M, these T8Ms cannot cut through big boulder obstructions and are
therefore generally suitable for soft ground excavation. Manual removal
of artifcial obstructions ahead of excavation or change of damaged
cutting tools cannot be done from behind the cutting wheel in most
of T8Ms due to no man access in the front bulkhead. To account for
unexpected ground conditions, the length of each drive is usually less
than 100 m.
A production rate of 6 8 m per day could be achieved in flling ground
with occasional boulders.
There is another type of T8M using this operating mode but has different
confguration in the cutterhead and thus the cutting tools (Fig 19.
Consisted of two main parts in the T8M and built of heavy gauge steel,
the front bulkhead of the frst part acts as support for the boring unit
and seals the front chamber for pressurisation. This part of the T8M,
called the shield, houses the machine operators porthole, a spoil screw
conveyor and an access chamber to the face of the T8M for manual
excavation under a compressedair working environment. The second
part is the telescopic tailskin which can extend to provide suffcient
thrust to the shield and is also used for connecting the precast concrete
pipes/ segments behind. An articulated |oint is provided between the
shield and the tailskin, to enable steering of the shield so that the line
and level of the pipeline can be ad|usted.
ln normal operation, this type of T8M is operated in closed mode, and
excavation is effected by a boom cutter or a minibackhoe connected
to an articulated telescopic arm mounted on a fully rotating turret in
clockwise or anticlockwise direction, and the mucking chamber is under
compressedair to balance groundwater. ln this mode, transportation
of the excavated materials is similar to that of the T8M with a cutting
wheel. ln order to prevent loss of compressedair, the excavated materials
in the screw conveyor are always kept full. When the T8M is operated
in open mode for removing obstructions manually, the triangular steel
panels hinged to the leading edge of the shield, which act as shutters,
are extended by hydraulic |acks operated from the drivers cabin, to
support the overlying ground during the operation.
There has been a case that the T8M was stuck in ground in the middle
of a drive, due to the accidental opening of a valve in the front bulkhead
which resulted in the ingress of soil and water in the T8M, causing
inundation and damage. This T8M was fnally recovered by a rescue
tunnel constructed from the receiving shaft, and the stalled pipeline was
then pushed to the receiving shaft through the rescue tunnel.
SIurry Pressure BaIance Method
Slurry pressure balance T8M (Figs 20 to 22, often called slurry shield, with
cutting bits and disc cutters installed at suitable locations in the cutting
wheel, of semidome type or dome type, is widely used to construct
pipelines in mixed to hard ground conditions under groundwater, to a
depth up to 30 m. Common sizes of T8Ms are 1,200 mm, 1,500 mm
and 1,800 mm.
The allowable |acking load in these T8Ms ranges from 500 to 1,000
tonnes(T, whereas the allowable torque pressure is in the range of
100 300 bar. The length of driving could vary from less than 50
100 m to more than 500 m passing through a number of intermediate
shafts in a single drive.
The works area required for |acking shaft is generally 7 8 m wide and
40 50 m long, for placing mobile crane, T8M control container, power
F/gurc 18 ~ Trunsortut/on oj FxcuvutcJ Mutcr/u/ /n !uckcJ P/c//nc
F/gurc 16 ~ Ty/cu/ P/cjuck/ng Works Us/ng Furth Prcssurc 3u/uncc T3M
(Courtcsy oj lcrrcnknccht 4C}
F/gurc 17 ~ Mcchun/sm oj Furth Prcssurc 3u/uncc McthoJ (Courtcsy oj
lcrrcnknccht 4C}
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
21
F/gurc 19 ~ Dcrut/on oj un FP3 T3M Us/ng M/n/buckhoc jor Fxcuvut/on (Courtcsy oj C5M 3F554C}
F/gurc 20 ~ Ty/cu/ P/cjuck/ng Works Us/ng 5/urry Prcssurc 3u/uncc T3M
(Courtcsy oj lcrrcnknccht 4C}
F/gurc 21 ~ Mcchun/sm oj 5/urry Prcssurc 3u/uncc McthoJ (Courtcsy oj
lcrrcnknccht 4C}
F/gurc 22 ~ Ccncru/ v/cw /ns/Jc u !uckcJ P/c//nc lnstu//cJ by 5/urry
Prcssurc 3u/uncc McthoJ
pack, generator, desander, muck tank, bentonite mixer, grab lorry, and
|acking pipes, etc. At certain locations, some equipment have to be put
on decks to suit the limited size of the works area as constrained by site
conditions, or a satellite works area has to be provided in the vicinity.
T8Ms of 900 mm in diameter or smaller may be incapable of tunnelling
through big rocks due to the size of the cutting wheel limiting the
number and size of the disc cutters. Therefore, advanced drilling to
determine the ground conditions along the pipeline alignment needs to
be carried out prior to commencement of the work to minimise the risk
of T8M stoppage and thus the rescue operation. There has been a case
that a 600 mm diameter T8M encountered fullface rock after leaving
the |acking shaft for about 1 m (Fig 23 and was stuck. The T8M was
fnally pulled back to the shaft and the rock obstruction was removed
by percussive drilling prior to resumption of tunnelling.
During the course of driving, bentonite based slurry, with a viscosity
of 40 50 Marsh sec for sandy ground, is constantly pumped into the
excavation chamber, through a slurry charge pipe. This forms a cake
over the excavation surface, to stabilise the face and prevent the ingress
of groundwater. The mix of slurry needs to be ad|usted to suit the
material in the excavation face. Sometimes, polymer has to be added to
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
22
slurry to increase the performance in adverse ground conditions, by, for
instance, decreasing the ground porosity or improving the properties of
the excavated materials in soft ground to maintain the ground stability
during excavation. The excavated materials are then pumped to ground
surface and then separated by a desander, with the slurry being recycled
for use and the spoil disposed of off site. For clayey ground, no slurry
is used and water under pressure is in|ected for the intended purpose.
Lubricant is also in|ected to the overcut along the pipeline, through
the lifting holes at the crown of the |acking pipes and the holes in
their axis, by an automatic system with preset timer and volume of
fow (Fig 24. lntermediate |acking stations, each with 8 12 nos 50
80 T hydraulic cylinders, are installed at predetermined locations of the
pipeline, usually every 80 100 m, to avoid excessive loading in the
main |acking station. However, no intermediate |acking station can be
installed in pipelines of 600 mm in diameter or smaller due to limited
space. ln addition, |acking pipes of such sizes do not have the holes
for in|ection of lubricant. Therefore, the |acking is generally limited to
short length, say 30 40 m.
For rock excavation, disc cutters, each with single or double discs, with
a diameter range of 200 300 mm, are equipped in the cutting wheel
and each disc cutter exerts a thrust of 20 30 T onto the rock face,
forming vertical and radial cracks in circular kerbs at distances of 60
100 mm. 8y repeated rotations of the cutting wheel and disc cutters,
these cracks are enlarged and eventually cause the rock mass in between
to be broken into small fragments. The fragments are further reduced in
size by the conical crusher at the rear of the cutting wheel, to a size of
not more than 40 mm in diameter. ln view of travelling a longer path
for excavation due to their positions, gauge disc cutters (ie near the edge
of the T8M usually require more frequent replacement than center disc
cutters (ie near the center of the T8M.
For T8Ms with a diameter of 1,500 mm or larger, a horizontal airlock is
generally provided at the rear for enabling inspection of the condition of
disc cutters and making necessary replacement, through the man access
in the front bulkhead, under compressedair. For tunnelling through hard
ground, a telescopic section is equipped in the T8M or an intermediate
|acking station is provided behind the T8M, to provide suffcient thrust
for excavation.
The advancement rate of T8M is 100 200 mm/min in soft ground
to 20 30 mm/min in hard ground. The T8M daily production rate
depends on the confguration of the T8M and could vary signifcantly
under different ground conditions.
8ased on DSD Contract No DC/2000/11 |5|, 2 m per day in hard
ground to 30 m per day in soft ground, with an average of 4.5 m per
day, could be achieved. A set of disc cutters is capable of completing
2 shallow drives and 1.5 deep drives respectively, under typical Hong
Kong soil conditions.
ln some cases, the pipeline has to pass through existing reinforced concrete
seawalls, requiring the affected portion to be completed by handdug
tunnel before the use of T8M to complete the remaining drive.
Cround SettIement
Tunnelling and pipe|acking would induce settlement in surrounding
ground. The magnitude of settlement is greatly affected by ground
conditions, type of tunnelling method, depth of tunnel and |acking
speed. The presence of underground utilities and services above the
|acked pipeline would lead to undermeasurement of surface ground
settlement due to their rigidity. lt is necessary to estimate the settlement
infuence zone and to assess its effect on nearby roads, structures
and utility installations such that they can be safeguarded during the
operation and remedial measures taken, if necessary. Maximum ground
settlement occurs at the center line of the pipeline and diminishes to
zero at a distance from its two sides.
F/gurc 2J ~ v/cw oj Fu//jucc Rock outs/Jc thc luunch/ng Fyc oj !uck/ng
5hujt
F/gurc 24 ~ ConJ/t/on/ng unJ lubr/cut/on jor !uckcJ P/c//nc
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
23
The ma|ority of ground settlement (70 80 occur during and immediately
after completion of tunnelling and pipe|acking works. Further settlement
would continue, and its stoppage depends on the ground conditions
above the |acked pipeline, for a few weeks to a few months.
Dated back to 15 20 years ago, the settlement was monitored using nails
installed on pavement. However, this type of installation is unable to detect
settlement accurately below rigid concrete pavement. ln a pro|ect, a road
collapsed due to the presence of cavities in ground without indication by
the monitoring data. After this incident, subsurface settlement markers, in
the form of a steel rod, by coring through rigid pavement, are generally
adopted, with their installation at suitable intervals along the alignment
of the pipeline and at offset at both sides, prior to commencement of
a pipe|acking drive. ln fexible pavement, nail markers are used. This is
supplemented by visual inspection that if settlement occurs, cracks would
develop in pavement. For structures sitting on shallow foundation, their
condition has to be assessed before commencement of tunnelling and
pipe|acking such that suitable monitoring devices such as tilt markers
and settlement markers can be installed to monitor the ground behavior
during the course of works.
Under normal situations, the monitoring is carried out once a day. This
frequency however may have to increase if there are abnormal readings
or the magnitude of readings changes abruptly. ln the event that if the
measured ground settlement exceeds the predicted value, the tunnelling
and pipe|acking works have to stop and an investigation on the cause, and
the damage, if any, carried out, with remedial measures such as ground
treatment implemented, as necessary, prior to resumption of work.
Through the proper operation of works, the ground settlement for most
of the pipe|acking drives using T8Ms could generally be controlled
within 15 mm for most of the Hong Kong soils, although excessive
ground settlement has been noticed in some drives due to unfavorable
ground conditions.
ControI of TunneI AIignment
The pipe|acking works in Hong Kong using T8Ms generally follow the
Tunnelling Specifcation |6| as guideline for controlling tunnel alignment,
in that a tolerance of 50 mm and 35 mm is specifed for line and level
respectively. For the 4 km long pipe|acking drives completed in DSD
Contract No DC/2000/11, under different ground conditions, 21 for
line and 19 for level exceeded the tolerance, generally by 2 50 mm,
despite the fact that the excavation face had been conditioned by slurry
and sometimes by the addition of polymer, as necessary. Moreover,
deviations in more than 100 mm were recorded at some locations in a
few drives where the ground conditions were alternating. ln addition,
about 2 of the pipelines exceeded the tolerated 0.5 degree angular
defection at pipe |oint, resulting in the need to carry out a detailed
inspection to ensure that there is no dislocation thereat. For excessive
opening in pipe |oint, remedial measures have to be carried out. This
could be achieved by locally trimming the concrete at the pipe end for
better bonding before applying norshrinkage epoxy, with a strength
equivalent to the pipe, to fll up the problematic location for prevention
of ingress of water.
The tunnel alignment is corrected by suitable extension or retraction of
the steering cylinders installed in the T8M. A T8M with 4 nos steering
cylinders has better control in alignment than that with 3 nos Outof
tolerance in alignment requires a long length to correct in order to avoid
causing damage to the |acking pipes.
For pipe|acking works using handshield for excavation and sleeve pipes/
segments to construct the temporary tunnel, no tolerance is specifed
for line and level as the tunnel will be large enough for installation of
the permanent pipeline. However, allowance has to be made to account
for the irregular profle of the tunnel, due to encountering different
ground conditions during excavation, which could affect installation of
the permanent pipeline therein to the required alignment.
For the tunnel formed by horizontal pipepiles or steel plankings/
channels, its alignment may need to be ad|usted to cater for unexpected
obstructions due to existing utilities and structures. ln the worst case,
the design of the permanent pipeline has to be modifed to suit the
actual site condition.
Rescue Operations
A T8M would be stuck in ground if obstructions are encountered during
excavation. lt is necessary to carry out a detailed investigation on its
cause, and then replacement of the damaged part from inside the T8M.
These obstructions could be natural or artifcial. lf the problem cannot
be overcome, the stalled T8M has to be recovered by means of a rescue
shaft or a rescue tunnel, as appropriate, with the obstruction removed.
The works would be delayed and new T8Ms may need to be deployed
for ensuring the completion of other pipe|acking drives on time, which
could disturb the programme of works.
8ased on DSDs Report No RD 1005/2 |3|, about 2 of the pipe|acking
works encountered obstructions, resulting in rescue operation.
The selection of a rescue option depends on many factors such as
the damage in the T8M, the location of T8M stoppage with regard to
its distance from the |acking shaft and the receiving shaft, the traffc
conditions, and the ground and groundwater conditions, above the
T8M, the constraints of utilities and services, and the effects on nearby
structures and facilities. The options may include but are not limited to
change of the damaged cutting wheel so that the T8M can continue
the remaining drive to the receiving shaft, removal of the T8M through
the rescue shaft and completion of the remaining drive by another
T8M from the receiving shaft to the rescue shaft, and construction
of a rescue tunnel from the receiving shaft, to overlap the T8M and
then the pipeline is pushed into the receiving shaft from the |acking
shaft. As each option involves different degree of risk, its suitability
needs to be assessed carefully, with site investigation works carried
out at and in the vicinity of the stalled T8M, before a decision is
made.
There have been two cases that a rescue shaft, formed by a combination
of sheetpiles and pipepiles, in the size of 1.8 m x 5.2 m on top and
2.5 m x 5.2 m at bottom and 16.5 m deep, and a rescue tunnel, with a
length of 35 m and an internal diameter of 2,440 mm, using compressed
air pressure to balance groundwater, took about 8 months and 10
months respectively for rescuing the stalled T8M, from investigation on
the cause of the problem, planning of rescue, construction, execution,
to recovery of the T8M |7|.
There has however been a case that a 1,350 mm diameter slurry
operated T8M encountered a steel box section when tunnelling in river
bed and could not advance further. The cutterhead of the T8M was
moved backward by retraction of the steering cylinders, to enable the
driving, vertically, of a 900 mm diameter steel pipe for encasing the steel
section. An attempt to completely lift up this steel section through this
steel pipe was carried out but breakage occurred at the location partly
cut by the disc cutters of the T8M, during the lifting operation. To enable
manentry for manual removal of the steel section, a steel plate, with a
prefabricated hole to accommodate the steel section, was installed in the
casing, with sandbags added on top of the plate to prevent uplift force
due to water pressure, and the ingress of water in the steel casing was
controlled by the use of a pump. The broken steel section was fnally
cut manually and removed, and the pipe|acking works resumed.
Some ProbIems Encountered
The following problems are commonly encountered during pipe|acking
works and could affect the progress.
For deep drive, high groundwater pressure requires additional |acking force
to advance the T8M against the pressure. Therefore, more intermediate
|acking stations have to be installed at suitable intervals of the pipeline
to ensure that there is suffcient thrust to push the pipeline forward. ln
addition, such high groundwater pressure also makes the T8M and the
frst few pipes moved back to the |acking shaft whilst new pipes are
being added. This always requires the temporary fxing of a steel bracket
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
24
in the T8M/ pipe to rigidly connect to the surrounding temporary works
as support during pipe connection.
A treated soil block, formed by grouting, is usually provided in the ground
outside the launching eye of the |acking shaft and the receiving eye of the
receiving shaft, to prevent ingress of water during the |acking/ receiving
operation and to support the T8M during launching and reception. ln
grounds with high content of boulders, the grout may not be able to
provide effective bonding between soil and rock. This would easily
cause dispersion in the grout block when the T8M is breaking through.
As a result, soil particles would migrate into the shaft, through the eye
location, and settlement would occur in overlying ground, damaging
utilities and services.
During the course of pipe|acking, zigzag line and level would occur
in the pipeline due to encountering different ground conditions. This
would require rendering in the depressed sections to provide a uniform
profle for the pipeline, affecting hydraulic performance. Excessive out
oftolerance would also cause openingup of pipe |oints, causing ingress
of groundwater and instability of the pipeline.
Cracking of concrete in pipe could happen at locations where there is
excessive deviation in line and level caused by uneven distribution of
|acking force, as a result of unfavourable ground conditions encountered.
This would require a temporary steel lining for protection to complete
the remaining drive before repair is carried out. ln the worst case, the
damaged pipe has to be repaired immediately, with the spalled or
defective concrete removed and replaced by high strength nonshrinkage
epoxy, before the pipe|acking works can continue.
When tunnelling through clayey ground, slow transportation rates in
the slurry discharge pipe always occurs, due to the plastic material
accumulated in the inlet of the spoil disposal chamber. This necessitates
high pressure water to disperse such material through the nozzles provided
nearby. Pipe blockage is also found when obstructions such as timber,
steel bars, etc are encountered, resulting in the long time to dismantle
the respective sections of pipes for clearance.
Wear or damage in disc cutters is a normal phenomenon in T8M during
tunnelling, and replacement has to be made at the right time to ensure
their proper function. There are however cases that they could not
be replaced from inside the T8M due to damage/ distortion of their
connections, affecting the cutting capacity and losing the function of
further advancement.
Excessive ground settlement or subsidence would occur in unstable
ground or due to improper control of the T8M, causing bursting of
watermains or gas mains. Although settlement monitoring is carried out
at regular intervals, this situation would still occur when there is a sudden
change in ground conditions not immediately noticeable to the
T8M operator for necessary ad|ustment in the T8M. Excavation in
bouldery ground or soft ground with boulders would also have such a
phenomenon.
Repeated extension and retraction of hydraulic |acks would cause
intermediate |acking stations to leak, due to the rubber seal being torn
out by such operation. This situation would be more critical in curved
alignments under eccentric loading throughout the drive. No repair could
be made until completion of the drive. lf the leaked location is near the
T8M, the tunnelling operation might be |eopardised.
ln porous ground, slurry in|ected from the T8M to balance groundwater
pressure would easily leak into ground, cause blockage to ductings of
utilities, and encroach into drainage features, affecting their function.
The tunnel alignment is affected by ground conditions during driving. lt
would be diffcult to control the alignment in soft ground with boulder
embedment or in alternating ground with soft and hard materials as the
T8M would tend to move faster towards soft materials. The hydraulic
performance of a pipeline would be affected should there be excessive
deviation in alignment.
A T8M would be stuck in ground if it cannot cut through obstruction
during the course of driving. This would result in the rescue operation,
and high frictional force would develop along the pipeline due to close
up of the annulus, causing diffculty to further proceed with pipe|acking
works.
Discussion
Appropriate SeIection of Method to Avoid DeIays
According to DSD Report No RD1005/2 |3|, about 75 of the pipe|acking
works were completed by T8Ms using the slurry pressure balance method,
1 by the earth pressure balance method and 24 by handdug tunnels.
However, there is a rapid increase in the use of handdug tunnels, in
the form of heading construction, in recent years.
Each of the pipe|acking techniques is benefcial when used in a proper
manner. lts performance is generally refected by daily production rate,
capacity in dealing with hard rock, control of line and level of pipeline,
and ground settlement or heaving. lt is therefore essential to choose the
appropriate method to avoid timely and costly remedial measures if the
work is stopped by obstructions or mechanical failure, which will cause
nuisance to the public and in turn lose the spirit of using them.
Cost of InstaIIation and Choice of Technigues
The cost of pipeline installation using such techniques does not vary
with depth except for the increased cost of providing deeper shafts and
manholes. ln comparison with the conventional opentrench method, the
cost of the slurry pressure balance method, the earth pressure balance
method, the free air handdug tunnelling method with grouting and the
compressed air handdug tunnelling method is higher in the order of 2 10
times, whereas the construction time is usually faster in most cases.
The choice of a technique lies with the designer or the contractor and is
dependent on the degree of risk that the pro|ect can accept. This is usually
governed by access, ground and groundwater conditions and accurate
identifcation and consideration of all other constraints. lncrease in site
investigation works would reduce the risk but could not eliminate it.
The earth pressure balance method, although relatively inexpensive of
tunnelling in soft ground, is unable to deal with large boulders and artifcial
obstructions. Although access to the face through the airlock chamber
in large T8Ms is feasible, their removal will be ineffcient due to limited
space and the use of only hand tools. 8reaking through the unknown
thickness of boulders will pose a risk that there may be a sudden change
in groundwater pressure endangering the worker. Therefore, the recent
trend is that slurry operated T8Ms have been used as a substitute to
minimise the risk of T8M stoppage due to the above problems.
The slurry pressure balance method has demonstrated its good rate of
progress in variable ground, but its use needs monitoring of excavation as
the machine advances to eliminate settlement (too much excavation, not
enough advance or heave (too much advance, not enough excavation.
Hence, the operators experience, training and response when problem
arises are crucial. Change of operator during the course of work should
be avoided as much as possible as the new operator would take a long
time before he becomes familiar with the T8M and the ground conditions.
The density, viscosity, fltrate water and shear strength of the slurry have
to be tested on a regular basis and changed when any of these exceeds
the specifed upper or lower bound limits to ensure its functionality. The
confguration in the cutting wheel should be capable of cutting through
extremely hard and abrasive rock and, on the other hand, excavating
soil effciently. The disc cutters provided have to be extremely wear
resistant and capable of taking the maximum thrust of the T8Ms. To
avoid excessive heat generation, disc cutters should be equipped with
water cooling system. Locally made discs are to be used with care due
to diffculty of controlling their quality during the heat treated process.
ln the event that a boulder zone is identifed ahead of the drive, it may
be necessary to stabilise the soil above the affected area to minimise
ground settlement caused by vibration or overexcavation during the
cuttingthrough operation. This would also help to control the line and
level of a pipeline. lt may be worthwhile to note that up to now, no
T8M is capable of cutting through large artifcial obstructions, especially
metallic ob|ects, resulting in its stoppage in ground.
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
25
ProbIems with TBMs
The type of cutting wheel and T8M to be used and the expected advance
rate depends on ground conditions and their variability likely encountered.
A radical and unexpected change of ground conditions can prevent a
drive from being completed and require rescue operation to permit the
work to be completed. Likelihood of obstructions, natural or artifcial, can
also prevent a drive from being completed, and the rescue of a stalled
T8M could be timeconsuming and expensive, affecting progress.
AdditionaI Features in New TBMs
Research in T8M technology has developed rapidly in recent years,
based on the problems encountered in different pro|ects under different
ground conditions. New T8Ms are now equipped with additional features
that allow increased and reliable performance under a range of ground
conditions. To account for the high variability in ground conditions in a
short length, which is a main characteristic in Hong Kong soils, mixed
ground slurry operated T8Ms have been widely adopted by contractors
to minimise the risk.
Advantages of Lubricant
Lubricant, applied along the |acked pipelines, has demonstrated to be
effective in lowering |acking forces and reducing the risk of pipe damage
in most of the pipe|acking drives. ln long drives, automatic bentonite
systems with programmable valves should be used to ensure that lubricant,
with the specifed volume, is in|ected to the annulus of the pipeline in
prefxed intervals, to serve the intended purpose.
Laser Cuidance System
ln straight drives, the position of T8M is determined by the guidance
system which relies on the laser beam transmitted from the laser device
installed at the rear of the |acking shaft, to the target plate installed in
the T8M. However, in curved drives, the laser technology with the use
of reference prisms and total survey stations is generally used in T8Ms
with diameters of 1,800 mm and larger. ln small T8Ms, the use of Cyro
compasses with hydrostatic grade correction is a common approach and
has demonstrated its accuracy.
ProbIems with Disc Cutters
The performance of disc cutters for pipe|acking works has a short history
in Hong Kong. ln 1990s, most of the works were carried out in single
drives, with a length generally not exceeding 100 m, and in shallow
depth. lt was until 1996 onwards that the scale of pipe|acking works
has increased to a few kilometres in a contract, with also deep drives
tunnelling through hard strata in ground. However, no complete record
on the respective performance could be traced except in DSD Contract
No DC/2000/11. This Contract showed that a total of 254 nos steel alloy
disc cutters, with a diameter range of 250 300 mm, had been used
for the 21 drives, averaging about 0.5 set of cutters for each shallow
drive and 1.5 sets for each deep drive. For T8Ms with a diameter of
600 mm to 1,800 mm, a set of disc cutters in the cutting wheel has
6 12 nos. Depending on the ground conditions encountered, particularly
the location, thickness and hardness of materials, some of the disc
cutters had to be replaced after the T8M had travelled a short length.
This situation occurred in some long, curved drives with highly variable
ground conditions and the replacement of disc cutters in a 4 m drive
length had been experienced in the worst case. Replacement of more
than 30 nos disc cutters during the course of works in three drives had
been recorded. lt is noted that a tunnel through moderately to slightly
decomposed granitic (M/SDC bedrock, with strengths of 320 350
MPa, achieved 4 m/day on average.
TunneI AIignment and LeveI Accuracy
Almost all the tunnel alignments, using T8Ms, can be controlled within
75 mm for line and 50 mm for level, as evidenced by DSDs three
contracts (Nos DC/95/05, DC/98/06 and DC/2000/11 which specifed
the use of tunnelling and pipe|acking techniques. ln consideration of
the steering capacity of the T8Ms available in the market, the angular
defection of the |acking pipes, and the procedure of correcting the outof
tolerance, a tolerance of 50 mm for line and 35 mm for level, as stated
in the Tunnel Specifcation, may not be applicable to all Hong Kong soils
for pipe|acking works, and hence should only be used with care.
Hand-dug TunneIs and Heading Method
The adoption of compressed air handdug tunnelling method would
face a problem associated with air loss in porous ground, giving rise to
the necessity of carrying out ground treatment to safeguard the tunnel
and the personnel working inside. The switch on of compressors and
generators around the clock to maintain the pressure in tunnel also
causes noise problem. Although high cost and relative low production
rate make this method only applicable to short drives, the removal of
artifcial obstructions can be warranted. However, after a few drives had
been completed under DSD Contract No DC/95/05, and following the
rapid development of T8M technology which allows pipe|acking drives in
curved alignment and detects obstruction ahead of T8M advancement,
this method has not been used in recent years due to the risk involved
and the reasons stated above.
Free air handdug tunnelling method in unstable ground would require
the entire length of the drive being grouted to maintain stability of the
road above, prior to commencement of work. Vertical grouting appears
to be infeasible due to presence of congested utilities and services in
shallow depths. Horizontal grouting will cause drawdown of groundwater
during the drilling operation and will blow out the ground or encroach
into ductings of utilities if the pressure is not properly controlled. lf the
grouting is ineffective, compressed air still has to be used to balance
groundwater pressure.
Heading construction is a method commonly adopted to construct
short pipelines crossing road |unctions, utility crossings and entrance
to carpark, in shallow depth. The completed works have demonstrated
its effectiveness due to fast mobilisation of plant, simple setup on site,
and fexibility in construction method to suit the space available. Due to
limited space, the tunnel excavation is generally carried out by hand tools.
There have been cases that unexpected fullface rock was encountered,
taking a long time for removal and affecting progress. Although problems
associated with safety, environment and ground stability could be a
concern, there is a growing demand in recent years that this method is
used to overcome site constraints, particularly those unexpected during
construction, thus minimising delay to the works.
All the above methods have merits and demerits. Their choice should be
based on technical compatibility with regard to ground and groundwater
conditions revealed by site investigation works, and other constraints
rather than only on cost. Detailed analysis of the risk, together with
the contingency plan, has to be given prior to fnalising the decision.
lnspection and maintenance of tunnelling shields, T8Ms and their backup
plant and equipment by competent personnel at regular intervals would
minimise the downtime and maximise the production. Since each pro|ect
is different in nature, it is advisable to consult with specialists in the feld
and T8M manufacturers in the planning stage to ensure success.
ConcIusion
The application of tunnelling and pipe|acking techniques for drainage
pipeline construction in Hong Kong has proved to be promising, generally
with less construction time and disturbance to the public, when compared
with the conventional opentrench method. Some of the problems could
have been avoided or minimised had suitable technique been selected
based on detailed site investigation results and site constraints, and proper
planning provided in advance. lt is essential to include comprehensive
rather than general requirements in the contract to fully cover each
activity of works, which should be practical and specifc with regard
to the situation encountered, with the contractors responsibility and
actions being clearly defned, so that arguments between the clients
consulting engineer and the contractor on problems, when occurring,
could be minimised. The experience, training and attitude of the working
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
26
and supervising personnel also have a signifcant effect on the success
of works.
Through the rapid development of T8M technology, long, curved
pipelines have been carried out in irregular, alternating soil and rock
composition at different depths, in recent years. Tunnelling through the
already completed permanent shafts has also been carried out, with
proper control of alignment, at a number of locations, to suit the pro|ect
programme. This also gives fexibility in selecting shaft locations to get
rid of utility and traffc constraints, as well as the disturbance problems
to shops, in most cases.
8y the installation of a sonic softground probing system in the T8M for
detecting hard materials in front of excavation and an electronic tool
monitoring system for detecting the wear limit of disc cutters, which is
the recent technology advancement in T8M, the risk associated with
T8M stoppage, as a result of obstruction, which is a common problem
in pipe|acking works, could be minimised.
Disc cutters have also been developed to have longer life and higher
capacity in dealing with the ground conditions likely to be encountered.
Artifcial obstructions still have to be removed manually should there
be access in the front bulkhead of the T8M. Otherwise, the T8M would
stop in ground necessitating rescue operation. This can be carried out
by means of either a rescue shaft or a rescue tunnel, which is a time
consuming and costly operation, affecting the progress of works and
disturbing the public. Therefore, site investigation should be carried out
as much as possible at suitable locations before the tunnelling method
and T8M is fnalised.
Tunnelling and pipe|acking techniques will continue to become popular for
installation of drainage pipelines in the urban areas of Hong Kong as they
could eliminate most of the problems encountered by the conventional
opentrench method and hence enable the works to be completed with
least inconvenience to the public and minimum diversion of existing
utilities and services, and traffc. These techniques are continually being
refned and developed. lmprovements cover both larger and smaller
diameters, longer drives, better control of alignment, faster and curved
driving, different ground conditions, and the ability to work deeper under
water. However, there are also certain constraints, such as no room for
construction of |acking and receiving shafts at suitable locations due
to congestion of existing utilities and hence the lack of space for their
diversion or close proximity to shops, insuffcient clearance between
overlying utilities and the |acked pipeline using T8M for advancement,
and unexpected underground artifcial obstructions, which limit the
application of such techniques.
AcknowIedgements
The authors wish to express their gratitude to the Drainage Services
Department of the Covernment of the HKSAR, for permission of extracting
the materials from the respective pro|ects, to publish this paper. Special
acknowledgement is given to Herrenknecht AC, and CSM 8ESSAC, for
their permission of extracting the photographs from technical brochures
in making Figs 16, 17, 20 and 21, and Fig 19 respectively.
References

1. Thomson, J., /|c(ock|ng onJ V|cro|unnc|||ng. pp36. 8lack A8P. UK (1993.
2. McFeatSmith, l., 7unnc|||ng |n /ong /ong |n ||c 1990:. Tunnelling in Hong
Kong Seminar. Hong Kong (1993.
3. Research and Development Section. Trenchless Pipe lnstallation and Renovation
Techniques. cv|cu oj /|c Iock|ng/ V|cro|unnc|||ng 7cc|n|uc: jor Con:|ruc||on
oj Dro|nogc /|c||nc:. Research 8 Development Report No RD 1005/2. Drainage
Services Department, Covernment of the HKSAR. Hong Kong (2002.
4. Mok, W.W.S., Mak, M.K.W. 8 Poon, F.H.T., Sewer lnstallation by Pipe|acking in
the Urban Areas of Hong Kong. Part l Planning, Design, Construction and
Challenges. 7|c ///F 7ron:oc||on:. Volume 14, No 1, pp2728. The Hong Kong
lnstitution of Engineers. Hong Kong (2007.
5. Mok, W.W.S., Mak, M.K.W. 8 Poon, F.H.T., Sewer lnstallation by Pipe|acking
in the Urban Areas of Hong Kong. Part ll Performance of Works, Lessons
Learned and lmprovements Proposed. 7|c ///F 7ron:oc||on:. Volume 14, No
1, pp3435. The Hong Kong lnstitution of Engineers. Hong Kong (2007.
6. The 8ritish Tunnelling Society and The lnstitution of Civil Engineers. Scc|co||on
jor 7unnc|||ng. pp36, 8688 8 106. Thomas Telford. UK (2000.
7. Mok, W.W.S., /|c(ockcJ 7unnc|: w|o| |o Jo /j o 7unnc| 5or|ng Voc||nc |:
S|uck |n CrounJ. Trenchless Conference in Macau. Macau (2007.
WiIson W S MOK BASc BA CEng R.P.E. (CiviI S
CeotechnicaI| CSci MICE MIMMM MHKIE
Email. wilsonwsmoknetvigator.com
lr Mok graduated from the University of Windsor
in Canada and has over 30 years practical working
experience in a wide variety of geotechnical and civil
engineering pro|ects in both design offce and site. He
is particularly experienced in dealing with design and
construction associated with geotechnical investigations
and instrumentation, deep excavations, tunnels, ground
improvements, settlement analysis, reclamation, site
formation, slope preventive measures, foundations
and sewerage works. lr Mok has been involved in the design, supervision and
administration of more than 16 km long trunk drainage pipeline construction in
the urban areas of Hong Kong, using different types of trenchless techniques from
relining, T8Ms to handdug tunnelling, and has carried out extensive research on
such. He is the author/ coauthor of several technical papers in this aspect, and his
paper titled Sewer lnstallation by Pipe|acking in the Urban Areas of Hong Kong,
in two parts, has been awarded the HKlE Transactions Prize 2007. He has been
Senior Resident Engineer on a DSD contract, which involved the construction of
4 km long trunk sewers, using pipe|acking techniques.
About the Authors
K W MAK BSc Dip HE DeIft PCLL MA Arb CEng
MIEAust MICE MHKIE MIHT
Email. kwmakdsd.gov.hk
lr Mak is currently Chief Engineer with Drainage
Services Department. ln the past few years, he has
participated in numerous largescale and prestigious
drainage and sewerage pro|ects, including the Wan
Chai East and North Point sewerage pro|ect, the frst
tertiary sewage treatment plant at Ngong Ping, the
largest ultraviolet disinfection facility installation at
Sin Ho Wan sewage treatment plant, as well as the
5 km long rainwaterintercepting tunnel in Tsuen Wan.
Previously, he spent six years in the then Works 8ureau dealing with slope and
water policies. During his earlier years with the Drainage Services Department, lr
Mak received postgraduate training in river engineering in the Netherlands, and
had then worked in the Shenzhen River Regulation Pro|ect. He obtained a Master
of Arts in the area of dispute resolution and arbitration. On top of his engineering
engagements, lr Mak acquires legal qualifcation and is a nonpractising 8arrister
atlaw of the High Court of the HKSAR. lr Mak is the coauthor of the paper titled
Sewer lnstallation by Pipe|acking in the Urban Areas of Hong Kong, which has
been awarded the HKlE Transactions Prize 2007.
7/F ///F 74NS4C7/ONS \o|umc 16 Num|cr 2
27