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Section 2 - Method Statement

1.0 References

2.0 Scope of Work

The purpose of this method statement is to identify a safe system of work and methodology of tunnelling
works using a closed face tunnelling equipment.

All personnel involved in the operation will be fully briefed on the contents of this document before the
works commence.

The Iseki Unclemole TCC micro-tunnelling machine can deal with all types of soft ground including mixed
face conditions. It will not deal with true rock but has the facility to crush cobbles up to a third of the face
450 mm in diameter. The system is a Full Face Support Slurry Tunnelling system which can pressurise the
face and work with a water head of 30m- designed to minimize face loss and therefore settlement.

3.0 Principal Health and Safety Considerations

3.1 Significant hazards

Working at height
Lifting operations
Plant and vehicle movements
Confine Space

4.0 Method (Indicate responsibilities/duties for each element where appropriate)

Method Responsibility

Before the construction phase, a number of documents and procedures will be

developed to ensure Project compliance with the relevant stakeholders.
Engineer
PIT BOTTOM SETUP
4.1 Ahead of any construction works a permit to break ground will be issued by the
Service coordinator who will study all the stats drawings and the tunnel cross
section drawings to ensure that tunnel line is not clashing with any services. A site
inspection will be carried out along the tunnel line to ensure that there are no
deep manholes that could clash with the tunnel to be constructed, The permit is Engineer
to be valid for the duration of the tunnel drive

4.2 Following the construction of the drive and reception shaft/pit the engineer will
calculate the alignment of the tunnel drive and bolt two steel plates on the top of Engineer /
the drive shaft. A slot will be cut with a hacksaw representing the centerline of
Ganger
the drive
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4.3 It is necessary for the base slab of the shaft to be placed min 700mm below the
tunnel invert. Two steel rails (launch rails) will be lowered in the shaft by using
straps chocked around them and once landed on the shaft base they will be set on
line/level indicated by engineer. Ganger

4.4 Vertical Steel RSJ’s will be installed between the launch rails and the shaft lining as
per position indicated in the temp works design (TWD). The RSJ’s will be lowered Pit bottom crew
in the shaft one by one, and will be strutted against the wall prior to the chain
being released.

4.5 A shutter will be placed along and on the back of the launch rails. A concrete skip Engineer /
will be used to place concrete in the shutter. See general arrangement at Ganger
Appendix A

4.6 The jacking rig will be lowered on the launching rails. Once the rig has been landed
in the shaft two operatives will enter the shaft and will begin fine adjusting of the
Pit bottom crew
rig line so that it is centered with the tunnel line. Once the engineer confirmed the
position of the rig, shuttering operations will begin to form the backwall as
detailed in the TWD.
Pit bottom crew
4.7 A decking platform will be built on each side of the jacking rig by using 9x3 timber
cut to size The timbers will span between the jacking rig support and steel L-shape
brackets bolted on the side of jacking rig.
Engineer
4.8 After the handrail will be placed along each side of the jacking rig, the slurry pump
will be placed on the decking and brackets will bolted to the shaft wall. A generic
layout of the pit bottom is attached at. Appendix B
Agent
TBM LAUNCHING

4.9 The point of exit for the TBM (tunnel boring machine) will be marked on the front
wall and the tunnel entry gland plate will be bolted to the wall.

4.10 HOLD POINT. Before breaking the eye, the borehole and shaft sinking records
must be consulted to ensure ground conditions will allow breaking the shaft lining
without the need for additional measures (ie ground stabilization, concrete jacket,
Ganger
jamb frame) that will prevent ground loss through the opening. The tunneling
department shall have previously been consulted to confirm that launching /
recovery method is suitable.

4.11 A circular hole will be broken in the shaft wall by using a 1.5t mini digger that can
sit and operate within the jacking rig

4.12 Once all the concrete and reinforcement is removed a rubber gland is fixed to the
steel plate by using mobile retaining plates that can be positioned tight against the
designed opening. This seal will prevent ground water and lubrication liquid
entering the pit or shaft during the tunneling process.

4.13 The machine (TBM) will be lowered in the shaft by the crane and placed in the
jacking rig. Two steel beams will be placed in the jacking rig frame and used to
 push the machine through the rubber seal gland. Once enough room is crated in Ganger
the jacking frame, a push ring will be lowered in the shaft a mounted in the jacking
rig frame. This push ring will be used from this stage to completion and it is
designed to transfer jacking loads uniformly around the pipe face.

4.14 TBM will be pushed until the face is reaching the open ground / concrete jacket (if
applicable). The slurry and lubrication pipes, power cable and telecom cables will
be connected to the machine. From the next pipe tunnel lights and air ventilation
will be bolted to the tunnel. See Appendix C for tunnel layout.

MICROTUNNELLING

4.15 The rotary action of the cutting head will excavate the ground at the front of the
Engineer
machine. The Iseki TCC micro-tunneling machine also incorporates a cone crusher;
this crusher can deal with cobbles up-to 450mm

4.16 A laser will be set up at the back of the rig to provide the line and level control for
the machine. Daily checks will be undertaken to ensure correct alignment. Any
Ganger (TBM
adjustments will be communicated to the TBM Operator and both Operator and
operator)
Engineer will sign the pipe record sheet to acknowledge.

4.17 The machine operator, working from the control cabin, governs the rate of
progress and is aided by a CCTV monitor viewing the laser beam hitting a target
set within the tunneling machine. The machine orientation can be adjusted using
steering rams within the machine. The rate of progress along with the slurry
Ganger
pressure is balanced to provide face support and thereby limit and control any
potential surface settlement.

4.18 When the machine is fully buried into the ground the operator will stop all pipe
jacking motion. Main Jacks will be retracted slightly to enable disconnection Pit bottom crew
works.

4.19 All power supply will be cut off, the control cables will be disconnected. The slurry
valves will be fully shut off to prevent slurry backflow from the separation/mud
plant. The slurry pipes will be disconnected in the pit bottom and once slurry
stopped running through the open ends, the flexible (Arizona) pipes will be lifted Pit bottom crew
by 2 people onto the decking. In order to keep cables dry and safe the invert of the
tunnel will be swept every time the lines are disconnected.

4.20 If any water or mud is found on the plugs or connector pins, clean it immediately Ganger/ Pit
with proper solvent (CRC contact cleaner) and blown off with air gun before bottom crew
connection.

4.21 Once all pipes and cables are disconnected the pit bottom team will inform the
TBM operator and pull back the jacking frame to allow a new pipe to be placed on
the rig. Stay clear of all hydraulic motion equipment during the retraction process. Pit bottom
crew/Slinger
4.22 The pipes to be installed shall be prepared in advance at ground level by using the
following sequence.

Check pipe collars and seal area of spigot for damage or defects.
Glue 18mm MDF packers on face of pipe (collar side)
 Glue a neoprene band along the perimeter of each steel collar
Place steel curved wheeled sleepers (built to provide cable /slurry pipes
positioning in the tunnel)
Place lubrication, slurry pipes and clamps inside the pipe to be installed.
Place lubrication control station (every 4th pipe)
Brace half-moon board at each side of the jacking pipe (to prevent fall of the
loose cables pipes stored inside the pipe whilst lowering into shaft)
Pipe will be lifted from the ground to waist level
Two operatives will place the pipe gasket seal on the spigot
Apply seal lubricant around the rubber. Seal lubricant is very slippery so
make sure you clean it off all equipment like rails and platform
Ganger/Pit
4.23 Once the slinger ensures that no people are in the shaft area a further concrete bottom crew
pipe is lowered until it reaches the jacking rig level. The pit bottom team will than
guide the pipe into the pushing position. This operation shall be done from the
decking. Once the pipe is lined up behind the machine the TBM operator will push
the jacking frame until the rubber placed around the pipe spigot fully enters the
collar of the TBM / pipe. Stop the operator if any section on the seals is found
dislocated from the adapter. During this operation the pit bottom team must be
vigilant of the movements of the pushing frame and ensure they stay clear to
avoid being trapped

4.24 The cables and pipes are then re-connected ensuring there is enough slack in the Pit bottom crew
cables to allow tunnel line to be advanced by another pipe length. Make sure all
cables are fully connected and kept tidy and safe away from any area with motion.
Inform operator once all tunnel services are connected

4.25 Operator will energise supply into tunnel and machine and commence pipe jacking
process. Always stay clear and be aware of all movements of the hydraulic
components.

4.26 After installation of approx. 10 – 15pipes an intermediate pump must be installed Pit bottom crew
to ensure the slurry can be pumped efficiently from the tunnel to the separation
plant. The pump will be lowered in the shaft by using the crane, and positioned
within the previously installed pipe. Flexible hoses will be used to line up the
pumps outlet with the slurry line that will be fixed in the curved wheeled sleepers.
Mud technician
4.27 Excavated material, suspended in the return slurry, is pumped back to the surface.
The slurry will discharge onto a de-sander unit where the large particles are
filtered and directed to a skip. The resulted slury will be discharged into a tank and
then cycled through a centrifuge unit where the smaller particles are separated
from the water and disposed to a muck skip. The recycled water will be pumped
back to the TBM face where it will be mixed again with the excavated spoil
creating slurry. See Appendix D for a generic layout of the micro-tunneling system
Mud technician
4.28 The excavated spoil, which has been separated from the slurry will be disposed on / Engineer
a muck skip and taken off site by a licensed carrier.
The quantity of excavated material will be monitored to ensure it is proportional
with progress rate. Engineer

4.29 Settlement monitoring will be carried out at the ground level to ensure there is no
settlement or ground heave. Mud technician
 / Ganger
4.30 Skin friction on the tunnel is reduced by a lubrication polymer which is diluted
with water into a lubrication plant and injected into the nominal annulus of the
excavated bore through the machine’s tail skin and through lubrication stations
dispersed equally along the tunnel line

4.31 This cyclic operation of installing jacking pipes continues until the machine reaches Engineer
the recovery position.

4.32 At intervals of maximum 10m or (daily) of tunnel progress the engineer will co-
plane the line from the top and survey if the pipe laser is indicating the correct Agent
alignment

4.33 In order to limit the thrust imposed by the jacking rig on the backwall, resulted
from the ground load and friction exercised during the tunnel drive, a number of
interjack stations (IJ’s) will be used to enable progress of different sections of the
tunnel. This loads and number of IJ’s required must be predicted ahead of the
drive through a temp works design (TWD).

4.34 The IJ’s is formed by 2 pipes : a lead pipe that has a series of hydraulic rams
mounted along the circumference and a trail pipe that has the facility to allow
extension of the rams and progression of the tunnel whilst maintaining the inner
face of the tunnel sealed from ground water / lubricant present outside the tunnel
line. Whilst the interjacks may be installed they may not be operated and piped
up- depending on the actual jacking & face pressures. Pit bottom crew

4.35 During the progress of the tunnel drive it will be required for the pit bottom gang
to enter the tunnel for various reasons (i.e. checks of the system, routine
maintenance of the pumps, clearing the slurry or lubrication building in the tunnel
for downhill drives). It is required that the all people entering the tunnel will have
gas detector and 10 min sets with them and line of communication will be
maintained to the top man through a bottom man located in the shaft. It is also
mandatory that all tunnel drive will have a forced air ventilation system
progressively installed.

TBM RECOVERY Engineer

4.36 When the machine reaches reception shaft, the exact position of the machine will
be surveyed and marked out on the shaft wall prior to any excavation to recover
Agent
the machine.

4.37 The method of recovering the tunneling machine will have to be assessed for
individual ground conditions applicable to each reception shaft. For this
document, the ground conditions considered are dry clay where no additional
measures are required for retrieval, apart from maintaining structural stability of
the reception shaft whilst breaking an eye through its lining. This shall be designed
by the temporary works department. In general this will consist of a steel gland
plate bolted to the lining once the TBM position has been identified.
Pit bottom crew
4.38 The concrete lining will be broken by a mini digger prior to placing the steel plate
and rubber if required.
 All
4.39 The machine will be advanced into the reception pit until the first lifting eye will
be inside the shaft. A chain/sling will be connected to the TBM by using a D
shackle. The lift supervisor will confirm to the slinger how much weight the crane
has to lift in order to maintain the line of the tunnel while the machine is jacked in
nd
the shaft. When the 2 lifting eye of the TBM is visible in the shaft, an operative
nd
will connect the 2 leg of the chain to the TBM, at this point a pit bottom
operative will enter the tunnel with a personal gas monitor, escape set and
required hand tools, traverse the tunnel to the TBM and disconnect the services.
Please note that prior to entry into the tunnel, all power (apart from low voltage
lighting and communications) including hydraulic energy will be isolated. The TBM
st
will then be disconnected from the rubber seal connecting it with the 1 pipe by
gently lifting and lowering the machine unit the TBM tail is released.
Ganger / Pit
4.40 Once machine is released from the rubber seal, a pit bottom man will go in the bottom crew
tunnel and disconnect the slurry pipes and cables from the TBM. Once TBM is
disconnected from all services, the operatives will clear the reception shaft and
the machine will be lifted onto a frame / lorry located by the shaft.

TUNNEL STRIPPING

4.41 If IJ’s are used than the component rams are the first to be remove following the
sequence below :

Place a cushion mat on the invert of the Interjack unit

Remove the plate connecting the rams into the IJ assembly. Ganger / Pit
Operator to extend the rams by 50mm allowing the rams to fall on the bottom crew
cushion. Stay well clear from this area
If any rams are not released, than use a short crow bar to dislodge them. Stay
clear during this operation
The supplied blanking caps must be fitted to all the interjack cylinder ports.
Ram cylinders to be placed outside the IJ rebate in order to enable for that to
be closed. Stay clear from the interjack
HOLD POINT
Before closing the inter jack ensure the pipe in the reception shaft is
adequately braced.
Push the tunnel line until the intejack unit is closed

4.42 The slurry pumps from the decking will be lifted out and the decking will be
removed on reverse installation sequence.

4.43 The jacking rig will be lifted out of the shaft and lunching rails removed. All
concrete debris will be cleared from the shaft floor.

4.44 Prior to removing the gland plates from both driving and reception pit the tunnel
annulus will be filled with grout pumped from on the surface, where it will be
mixed in a grout pan. Grouting of the line will be done by using the holes that
were used for lubrication during the drive
 4.45 An air winch will be bolted onto the concrete backwall. The tunnel will be cleared
in sections starting from the driving pit. The cables and pipes will be disconnected
allowing the curved wheeled sleepers to be rolled back in the driving shaft by
pulling them with the winch. The slurry/ lubrication pipes will be placed in a steel
stillage and lifted from the shaft after all operatives have cleared the lifting area.
4.46 Once the striping progresses to the IJ area the rams removed from the assembly
earlier will be each lifted by 2 people onto a tunnel boogie and pulled back in the Engineer
driving pit by the winch. The lubrication stations will be disconnected from the
jacking pipes and placed on the same boogie

4.47 Mortar will be mixed on the ground level and placed in buckets that will be
lowered in the shaft by using a tunnel skip. The buckets will be placed on the
boogie and pushed in the tunnel where the lubrication holes will be filled

4.48 The tunnel is to be inspected by the engineer who will sign that the tunnel is ready
for commissioning. The last sequence is to remove the tunnel lights starting from
the reception pit and working back towards the driving shaft.

5.0 Plant, Equipment and Labour

Tunneling kit Excavator Confine space kit (incl. rescue)

Crane 360kva Generator +Backup
2 x 4” Submersible pumps Backup Generator

Labour Requirements
Management/supervision/For Excavator driver Crane operators
man
Engineers Surveyors Slurry Plant operatives
Traffic Marshalls Banksman Telehandler operatives
Security Slingers/signallers Tunnel ops
Shaft ops Surveyors Electrician/fitters

6.0 Other Considerations

7.0 Appendices (list & attach all applicable assessments i.e. HAVS, Manual Handling, COSHH,
Noise, lifting plans etc)

Appendix E - Manual Handling Assessment

Appendix F - HAVS Assessment
Appendix G - COSHH Assessment
Appendix H – Confined Space Category Map

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 8.0 Enclosures

Appendix A - LAUNCH RAIL / VERTICAL RSJ’s ARRNAGEMENT

Appendix B - LAYOUT OF PIT BOTTOM DURING TUNNELING
Appendix C - JACKING PIPE INTERNAL LAYOUT
Appendix D - MICROTUNNELING GENERIC LAYOUT

Confirmation of Risk Assessment & Method Statement Briefing

Prior to commencing the activities covered in this safe system of work document all personnel are to sign
below to confirm that a clear briefing explaining the job has been given and is understood:
Name Signature Date Name Signature Date
Safety Communication Quality Integrity TeamSpirit Caring Trust Pride

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 Safety Communication Quality Integrity TeamSpirit Caring Trust Pride

APPENDIX A - LAUNCH RAIL / VERTICAL RSJ’s ARRNAGEMENT

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APPENDIX B - LAYOUT OF PIT BOTTOM DURING TUNNELING
APPENDIX C - JACKING PIPE INTERNAL LAYOUT
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APPENDIX D - MICROTUNNELING GENERIC LAYOUT

APPENDIX E - Manual Handling Assessment

Microtunneling Slurry Pipes

No

Use mechanical lifting as first line of address

Operatives to share loads
Keep back straight and bend at knees when lifting

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APPENDIX F - HAVS Assessment

DATE
OPERATION /
SITE OPERATOR

HAND-ARM VIBRATION EXPOSURE CALCULATOR

Time to time in
Vibration reach EAV min Time to reach ELV Exposure Partial Partial
2 2
2.5 m/s 5 m/s
magnitude A(8) A(8) time in duration exposure exposure
m/s² r.m.s. hours minutes hours minutes hours minutes m/s² A(8) points

Notes / Controls: Daily Total

exposure exposure
m/s² A(8) points

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Appendix G - COSHH Assessment
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Appendix H – Confined space categorisation process map

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