Resource Management

Trenchless Construction Methods

Hesham Osman
Associate Professor
Cairo University
Trenchless Technologies
What are Trenchless Technolgoies?
Trenchless Technology is a technique for underground
pipeline and utility construction and replacement with minimum
or no excavation from the ground surface

What is Open Cut

Excavation?
Involves digging a
trench along the
proposed pipeline
route, placing the pipe
in the trench on a
suitable bedding
material, and then
backfilling.
Trenchless Technologies
Trenchless Technology
Trenchless Construction
Method (TCM)
• All trenchless
construction methods
where a new utility or
pipe in installed
Trenchless Renewal
Method (TRM)
 Trenchless methods
that involve the
rehabilitation or
upgrade of an existing
pipe and extends its
service life
Advantages of Trenchless
Technology
• Minimize traffic disruption
• Less exposed work site  Improved construction safety
• Eliminates need for pavement restoration
• Minimizes chance of disturbing existing utilities
• Minimizes damage to nearby buildings
• Less disruption to the public (noise, pollution, etc…)
Microtunelling
• Pipe jacking, generally referred to in the smaller diameters as
microtunnelling, is a technique for installing underground pipelines,
ducts and culverts.
• Powerful hydraulic jacks are used to push specially designed pipes
through the ground behind a shield at the same time as excavation
is taking place within the shield.
• There is no theoretical limit to the length of individual pipejacks
although practical engineering considerations and economics may
impose restrictions. Drives of several hundred meters either in a
straight line or to a radius are routine. A number of excavation
systems are available including manual, mechanical and remote
control. Pipes in the range 150mm to 3000mm, can be installed by
employing the appropriate system.
Microtunelling
• In order to install a pipeline using this technique, thrust and
reception pits are constructed, usually at manhole positions.
• A thrust wall is constructed to provide a reaction against which to
jack. In poor ground, piling or other special arrangements may have
to be employed to increase the reaction capability of the thrust wall.
• High pressure jacks driven by hydraulic power packs provide the
substantial forces required for jacking concrete pipes.
• To ensure that the jacking forces are distributed around the
circumference of a pipe being jacked, a thrust ring is provided of a
design dependent on the number of jacks being used. The jacks are
interconnected hydraulically to ensure that the thrust from each is
the same. The number of jacks used may vary because of the pipe
size, the strength of the jacking pipes, the length to be installed and
the anticipated frictional resistance.
Microtunelling
1 Control and steering
desk,
2 Crane
3 Jacking pipes,
4 Separation plant
5 Mixing plant,
6 Supply pump
7 Shield machine,
8 Intermediate jacking
station
9 Main jacking station,
10 Abutment/Thrust
Block

Minimum cover = 2m or 2*pipe diameter

Shaft Construction
• Entrance and exit shafts are constructed using:
▫ Diaphragm Walls
▫ Secant Piles
▫ Shaft Sinking
▫ Sheet Piles
▫ Others….
• Shaft will be eventual position for manhole, valve chamber, etc…
• Entrance seal (rubber/steel) or a soft eye (concrete with limited or
no reinforcement) to allow breakthrough of microtunnel
Drilling Fluids
• A mix of water, bentonite, polymers and speciality chemicals used for a
large number of trenchless applications. They provide:
▫ Support for the sides of excavation
▫ Pipe lubrication
▫ Medium to transport the excavated material
• The bentonite or drilling mud clays are generally formed from volcanic
mineral (montmorillonite) clays
• The name comes from the mining area of Fort Benton Wyoming
• The bentonite is supplied to the site in a powdered form. When added
to water in its dry powder form the bentonite is blended to form a
viscous (thick and sticky) fluid.
• When the clay particles are thoroughly mixed and hydrated or soaked,
this causes the particles to bond to each other evenly and swell to form
a gel. If the bentonite is left to stand for a period of time it forms a gel
or bonding of the swollen clay particles.
Bentonite Quality Control
• Control of density by the mud balance
• Control of viscosity by the March funnel
• Sand control by the sand content tube
• Filtration property and filter cake property control by
the filter press
 Guidance & Remote Control Systems
• Laser is the most commonly used guidance system for MT.
• It gives line and grade information for the pipe installation.
• The laser is installed in the drive shaft and gives a fixed reference point
as to the line and grade. The laser target and a closed-circuit television
(CCTV) camera are installed in the rear of the MTBM to monitor the
target.
• Laser Target Types:
▫ Passive System: target grid is mounted in the MTBM. CCTV monitors this target, and
the information obtained by CCTV is transferred to the operator’s control panel
▫ Active System: photosensitive cells are installed on the target, and these cells convert
information into digital data. The data is electronically transmitted to the control panel
and gives the operator digital information of the line and grade
Forces during pipe jacking
• Length, alignment, and
outside dimensions of the
pipeline to be jacked
• Weight of pipe (the jacking
loads can be estimated as 50
percent of pipe or box culvert
weight)
• Height of overburden
• Nature of soil and watertable
and effects of dewatering
• Loads on shield (both skin
and face pressure on the
shield or TBM)
• Whether operation is
continuous or interrupted
• Amount and type of
lubrication
Forces during pipe jacking
Calculating jacking forces is important for:
• Selecting the jacking pipes based on the
permissible jacking force
• Determining the jacking length and
spacing of the shafts or intermediate
jacking stations
• Designing the drive shaft and the thrust
block
Coefficient of Friction
 Face pressure

Face pressure needs to be

controlled throughout the
tunnelling process

Face Pressure > Active

Earth Pressure  This
ensures that surrounding soil
does not enter the chamber

Face Pressure < Passive

Earth Pressure  This
ensures that soil failure does
not occur in front of the
drilling head
Types of Pressure Balancing Systems:
Earth Pressure Balance (EPB)
• For soft, cohesive soils tunnel boring
machines with earth pressure
support are a preferred option. So
called Earth Pressure Balance
Shields (EPB) turn the excavated
material into a soil paste that is used
as pliable, plastic support medium.

• This makes it possible to balance the

pressure conditions at the tunnel
face, avoids uncontrolled inflow of
soil into the machine and creates the
conditions for rapid tunnelling with
minimum settlement.
 Microtunelling Summary
Item Description
Diameter 300-3000mm
Range Most common ranges 600-1500 mm
Drive lengths 150 – 450 m are common

Soil Slurry Shield Mictrotunnel: Wet Sand

Conditions EPB Microtunnel: Clay
Productivity 10 - 25 m per 8 hour shift
Range
Accuracy Within 2.5 cm accuracy with advanced guidance systems
Major • Cost effective in deep excavations
Advantages • High accuracy in installation
• Product pipe is jacked directly, no need for casing pipe
• Versatile over different ground conditions
Major • High capital cost for equipment
Limitations • Inability to use low-strength or plastic pipes
Pipe/Box Jacking
• The term pipe or box jacking can be used to describe an installation
• technique as well as a trenchless technology process.
• When referred to as a process, the term implies the use of thrust boring and
pushing pipes or boxes using hydraulic jacking force. This concept of a
―jacking system‖ is adapted by many trenchless technologies including
horizontal auger boring, and microtunneling
• In the next few slides, the term pipe or box jacking is regarded as a
conventional installation technique.

• Pipe or box jacking (PBJ) is a trenchless technology method for installing a

prefabricated pipe or box culvert through the ground from a drive shaft to a
receiving shaft. The most basic approach of box jacking, which is still widely
used, is where a prefabricated box structure is located on a launch pad,
adjacent to where it is to be installed, and is jacked into the ground with
excavation taking place within an open face shield.
• PBJ requires worker entry and hence is limited to larger diameters
Pipe/Box Jacking
 Pipe/Box Jacking Summary
Item Description
Diameter 1200-3000mm
Range Most common ranges 1200-1800 mm
Drive lengths 150 – 450 m are common

Soil Medium – stiff clay

Conditions Medium – dense sand above the water table
Productivity 10 - 20 m per 8 hour shift
Range
Accuracy Within 2.5 cm accuracy with advanced guidance systems
Major • Cost effective in deep excavations
Advantages • High accuracy in installation
• Product pipe is jacked directly, no need for casing pipe
• Versatile over different ground conditions
Major • High capital cost for equipment
Limitations • Inability to use low-strength or plastic pipes
Pipe Ramming
• Pipe ramming is a trenchless method for installing steel casing pipe
under roads, railroads and other structures. The casing is installed
open ended, which allows the soil to enter the casing. Containing the
soil in the casing minimizes the potential for surface settlement,
which allows the casing to be installed at relatively shallow depths
and in difficult soil conditions including flowing sands, gravel,
cobbles, and boulders
Pipe Ramming
• Pipe ramming is a straightforward process. The product or casing pipe,
fitted with a cutting shoe and lubricant pipes, is positioned on rails located
on a stable platform, which allows the casing to be pushed into soil
embankment on the designed alignment. A pneumatic hammer powered
by compressed air is attached to the casing using a cone or collet/collar
system. The ram hammers the open ended casing pipe through the soil to
the exit area. Additional pipe lengths may be welded onto the casing
periodically to lengthen the drive.

Some soil may be removed during

installation to reduce frictional drag of
the casing but enough soil is kept in the
casing until the completion of the drive
to maintain a plug at the face of the
casing. The soil contained in the casing
when the drive is completed is removed
typically by water or by air-pressure, or
in the case of larger casings by auger.
Pipe Ramming
Major Advantages Major Limitations
• effective method for installing • minimal control over line and
medium- to large-diameter grade.
pipes • In the case of obstructions,
• versatile pit sizes, such as boulders or cobbles,
• ability to handle almost all especially with small-diameter
types of soil conditions pipe, the pipe may be deflected
• does not require any thrust • High noise levels,
reaction structure
• Multifunctional: A single size
of pipe ramming tool and the
air compressor can be used to
install a wide variety of pipe
lengths and sizes
Horizontal Auger Boring
• Auger boring is the process of simultaneously jacking casing through the
earth between two pre-sunk shafts while removing the spoil inside the
encasement with a rotating flight auger.
• The casing supports the surrounding soil as spoil is systematically removed.
As a general rule, auger boring has poor steering capabilities.
• There are two types of auger boring: track type and cradle type. The track
type method consists of a track system, machine, casing pipe, cutting head,
and augers. The boring operation is cyclic, as pipe segments and auger
flights are added after a prescribed auger flight length is installed.
Horizontal Auger Boring
• Thrust is developed by hydraulic rams located at the rear
of the boring machine. One end attaches to the end of
the boring machine while the other attaches to lugs
connected to the track system.
• No rotation is applied to the casing as it is jacked
through the soil by hydraulic thrust rams located at the
rear of the machine. Lubrication is used to reduce skin
friction and to aid with soil cutting and transport
 Horizontal Auger Boring Summary
Item Description
Diameter 100-1500mm
Range Most common ranges 200-900mm
Drive lengths 30-120 m
Soil Most soils is OK except for: Very loose dry sand and soils with
Conditions significant boulders and soils below the water table
Productivity 7 - 28 m per 8 hour shift
Range
Accuracy 1% of length of the bore
Major casing is installed as the borehole excavation takes place. Hence,
Advantages there is no uncased borehole, which substantially reduces the
probability of a cave-in,
Major • requires different-size cutting heads and augers for each casing,
Limitations which entails a substantial investment in equipment.
• Very limited steering capacity  Correct initial setup is vital
 Horizontal Directional Drilling (HDD)
• A pilot bore is made with a suitably sized
drilling rig.
• The bore is steered to create an initial hole at
the required line and grade.
• Successive reamers are then pulled back to
enlarge the hole diameter to the desired size.
• Typical pipe materials: PVC, HDPE and steel
Horizontal Directional Drilling -
HDD
• During the last stage of the reaming, the service
pipe is pulled back into the bore.
 HDD Drilling Rigs
Drilling fluid typically not required

According to their typical

application areas, the HDD drill
rigs are divided into three major
sectors—large-diameter HDD
(Maxi- HDD), medium-diameter
HDD (Midi-HDD), and small-
diameter HDD (Mini-HDD, also
called guided boring).

Although there is no significant

difference in the operational
mechanisms among these systems,
the different application ranges
often require corresponding
modification to the system
configuration and capacities, mode
of spoil removal, and directional
control methods to achieve optimal
cost efficiency.
HDD system components
• directional drill rig sized for the job at hand;
• drill rods linked together to form a drill string for advancing the drill bit
and for pulling back reamers and product pipes or cables;
• transmitter/receiver for tracking and recording the location of the drill and
product;
• tank for mixing and holding drilling fluid/mud;
• pump for circulating the drilling fluid/mud;
• drilling bits, reamers, swivels and pulling heads.
HDD tracking & locating
Walkover Tracking
• Transmitter is powered by a
battery
• Tracking not possible under
water bodies and at depths
exceeding 25m
In-Line Tracking
• Transmitter is powered by
external electrical supply with
an in-line wire within the
drilling rods
• Wire needs to be spliced every
time a new rod is installed.
Slows down the installation.
HDD Drill Rod Radius of Curvature
• A conservative industry guideline (ASTM F1962) indicates the
minimum radius of curvature of the drill rods should be
approximately

where (Rrod)min = minimum radius of curvature of drill rod, ft, and

Drod = nominal diameter of drill rod, in.

In practice, drill rod manufacturers may allow a lower radius of curvature. The
corresponding allowable degree of curvature or bending applies to bends in all
vertical (profile), horizontal (plane), or inclined plane.

Note that in Maxi-HDD operations, due to the large diameter of product

(carrier) pipes being installed, or their relatively high stiffness, the minimum
bore path radius of curvature may also be dependent on the product pipe
diameter. However, HDPE pipe has a minimum bending radius less than the
drill rod.
 HDD Summary
Item Description
Diameter Range 50-1500mm
Drive lengths 120 – 1500 m for Midi/Maxi
Up to 180m for Mini
(Note: Smaller lengths are possible but not economic)
Soil Conditions Most soils is OK except for: Soils with significant boulders and weathered
rock
Productivity Mini HDD typical range of 100-160 m per 8 hour shift.
Range Highest productivity among TCM
Accuracy 1% of length of the bore
Major • High steering capability. Ability to be pulled back and steered around
Advantages obstacles
• No drive/reception shaft is needed
• Quick set up time and high productivity rates
Major • Disposal of bentonite needs to be planned
Limitations • Pipe material is limited to that can be continuously strung together and
pulled as one piece
Considerations for selecting
trenchless technologies
• Diameter Range: The range of diameters for which the
TCM can install a pipe.
• Drive length: The maximum length of a drive that is
possible for a particular TCM
• Accuracy: The tolerance of the installation TCM. This
attribute is most pertinent in congested areas and during
long drives. The actual accuracy of any particular
technique will depend on the surrounding soil conditions
and the drive length.
Considerations for selecting
trenchless technologies
• Work space requirements: This is further described by
the workspace size, the need for a shaft/pit whether it is
a driving or receiving shaft and the need for installation
of thrust blocks within the pit.
• Soil Conditions: Describe the favorable and unfavorable
soil conditions for a particular TCM.
• Productivity Range: Describe the expected advance rate
for a particular TCM. This rate depends on the soil
conditions, pipe diameter, required accuracy and drive
length.
Considerations for selecting
trenchless technologies
• Cost Range: Describes the expected cost for using a TCM
that is usually a function of pipe diameter, soil
conditions and drive length.
• Maneuverability around obstacles: Describes the ability
of the TCM to maneuver around subsurface obstacles
that might be encountered during advancement.
• Obstacle detection: Describes the ability of the TCM to
detect obstacles that might be encountered during
advancement.
Considerations for selecting
trenchless technologies
• Spoil disposal: Describes the kind of spoil that needs to
be removed during advancement if any. Generally spoil
removal will either be for soil or slurry/soil combination.
This attribute is of importance due to environmental
concerns for spoil disposal.
• Noise: Describes the level of noise associated with a
particular method. Although the noise level will depend
on the equipment used, hammering methods like pipe
ramming will likely produce the greatest amount of
disturbance.
• Subsurface subsidence: Describes the process of soil
settlement during tunneling that might occur when using
a particular TCM.
Summary – Trenchless Construction Methods

Indicative only
Summary – Trenchless Construction
Costs
< 300 mm 300- 600- > 1500 mm
600 mm 1500mm
Microtunelling N/A $3,200 $10,000 $ 23,000

HDD $200 $ 620 $ 2,800 N/A

Pipe / Box N/A N/A $ 4,000 $ 7.200

Jacking

Costs / meter based on 2012

US Cost Data (Najafi, 2013)
Useful links
▫ North American Society for Trenchless Technology
http://www.nastt.org/
▫ International Society for Trenchless Technology
http://www.istt.com/