Trenchless Construction of Phase IIIA

District Cooling System (DCS)

By TBM Pipejacking
on Kai Tak Development
26 October 2016

Presented by :
Ir Wilson W. S. Mok
FICE CEng FHKIE RPE(Civil and Geotechnical)

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Kowloon Bay

Kwun Tong Typhoon Shelter

Kai Tak Approach Channel

Location Plan
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Scope of Works

• 2.5 km of Alignment Length of District Cooling System

1.6 km by Open Trench

0.8 km by TBM Pipejacking Method

0.1 km by Hand-Dug Tunnelling Method

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SHING CHEONG ROAD

Jacking Pit (-20.5 mPD) at
Shing Cheong Road and
HOSPITAL CEP Cheung Yip Street

2 nos. of DN 2800
Kai Tak Approach Channel Pipejacked Tunnel, each
350m Long

SHING FUNG ROAD Receiving Pit

(-20.5 mPD) at Kai Tak
Runway

Layout Plan Showing Locations of Working Pits

and TBM Pipeline Alignments of Sub-sea Tunnel
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Wilson W.S. Mok Open Trench

Open Trench
1 x 2800mm dia. TBM
(~140m long)
1 x 1200mm dia. TBM
2 x 1500mm dia. TBM
(~32m long each)

1 x 1200mm dia. Manshield

Pipejacking Method
2 x 1500mm dia. Manshield
Pipejacking Method
Open (~21m long each)
Trench

1 x 2800mm dia. TBM 1 x 1200mm dia. TBM

Hand-Dug (~142m long) 2 x 1500mm dia. TBM
Tunnel (~165m long each)

Open
Trench

Layout Plan Showing Locations of Working Pits

and TBM Pipeline Alignments
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Tunnel Boring Machine

Jacking Shaft 隧道鑽挖機

Typical Arrangement for

TBM Pipejacking Works
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Advantages of Adopting Pipejacking Techniques

(in Comparison with Conventional Open-trench Method)

• Less disturbance to traffic

• Faster
• Less ground settlement
• Diversions of utilities limited to only the jacking and receiving shaft
locations
• Less environmental problems
• Earth moving is reduced to a minimum
• Operational almost in all weathers
• Fully automatic operation, thus ensuring the safe and efficient completion
of works on time

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Method of TBM Pipejacking

• Earth Pressure Balance
• Slurry Pressure Balance

Choose Slurry Pressure Balance Method in the Project due to Highly Variable
Ground Conditions

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Construction Method – Pipe Jacking

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Section A-A

A B C

Side Elevation

Section B-B

Front View and Side View Section C-C

Configuration of 2800mm dia. TBM

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TBM Control Panel

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Pipejacking by Slurry Pressure Balance Method

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9 5
10

3
2 6
7 1
4
11 8

Circular Path in Rock Face

Formed by Cutting Discs

Pipejacking Operation –
Disc Cutters Cutting Analysis
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Mechanism of Rock Cutting by Disc Cutter

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Circular Kerfs in Rock Face Formed by

Disc Cutters
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Section A - Sub-sea Tunnel

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 Wilson W.S. Mok 5. Backfilling and
reinstatement

1. Construction of 1. Construction of
Receiving Pit Jacking Pit

Cheung Yip Street

Kai Tak Runway
4. Construction of chamber (+5mPD)
(+5mPD)
and pipes connection

Kai Tak Approach Channel

25m

10m 2. Construction of 2 nos. of DN2800

tunnels by pipejacking using TBM

-20.5mPD -20.5mPD
3. Laying of 1xDN1000 and 1xDN900
DCS pipes in each DN2800 tunnel
Sheet Piles Sheet Piles
350m long

Construction Sequence
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Site Investigation in Seabed

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JACKING +5.0 mPD
PIT +3.0 mPD
EXISTING SEAWALL
N
N = 13 FILL
= 46
N
N =4 MARINE DEPOSIT
=4 N
=6

-20.5 mPD ALIGNMENT of 2 x 2800 mm DIAMETER PIPELINES

N
= 31 N ALLUVIUM
N = 28
= 20

+5.0 mPD RECEIVING

EXISTING SEAWALL PIT
+3.0 mPD
FILL N N
= 16 = 15
N
N
= 21 = 13
N N
=6 MARINE DEPOSIT = 10
N
= 18
N
N N
=4 -20.5mPD =7
= 20 -20.5 mPD

RECEIVING
PIT
N
= 28 ALLUVIUM
N
= 28 N
= 22 N
= 25 N N
= 31 = 16

Inferred Geological Profile

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Typical Arrangement of Jacked Pipeline

with Intermediate Jacking Stations
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Sloping seawall
LEGEND made by rubble

PROPOSED CROSSING

SUB-SURFACE SETTLEMENT
MARKERS

TILT PLATE

PIEZOMETER

EXTENSOMETER

INCLINOMETER CA2 ROAD

Vertical
seawall made
Of concrete
blocks

Geotechnical Instrument Plan

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 STEEL COVER WITH HINGED
OPENING
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THICKNESS VARIES
ROAD SLAB

∅
PVC TUBE

SAND FILL

600mm (MAX.)
∅ REBAR WELDED
VERTICALLY AND
CONCENTRIC WITH A
75 x 75 x 5mm THK. STEEL
PLATE

ELEVATION

75 x 75 x 5mm THK. STEEL PLATE

∅ 
PLACED CONCENTRIC WITH THE
PVC TUBE ON UNDISTURBED GROUND

PLAN

Typical Details of Sub-surface Settlement Markers

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Settlement Marker
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Installation of Settlement Marker

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Completed Settlement Marker

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Settlement Trough
Settlement Profile

Ground Level
Wmax
C
Zn

r
2r = D TBM
Tunnel Axis

Tunnel Lining

Longitudinal Settlement Profile From O’Reilly and News (1982)


  
2
Settlement Trough Width where i = 0.43Zn + 1.1 (cohesive soil)
CL
Ground Level -2i -i i 2i I = 0.28Zn – 0.12 (granular soil)
Assume overcut = x mm
0.61Wmax Wmax  
   2    2  
C
4
Zn i = Point of inflexion or maximum gradient
VS = Volume of Settlement Trough

D
r

Transverse Settlement Profile

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S
S = Maximum settlement at Centre Line of Tunnel

Settlement Trough for One Tunnel

Settlement Trough for Two Tunnels

Settlement Trough for Three Tunnels

Typical Shape of Settlement Trough

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JACKING PIT

HOSPITAL CEP SITE

General View of Jacking Pit at Excavation with Lateral Support

Cheung Yip Street and Shing for Jacking Pit
Cheong Road

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 GL

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Sheetpiles
GWL

2.8m Dia. TBM

Treated Soil
Block for TBM
Hydraulic Pushing Launching
Cylinders

Thrust
Wall
3000

10000
TBM
FL

3000

5000

Grout Zone

Typical Arrangement of Jacking Pit

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 5000
Treated Soil Block
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Note: Mok soil block formed by BC
grout followed by chemical grout
1st 2800mm
diameter jacked
Treated Soil Block pipeline

3000 3000 3000 Treated Soil

Block

14600
Jacking Pit
Sheetpile
1st2800mm 2nd2800mm
diameter jacked
pipeline
3000 diameter jacked
Grout Hole
pipeline

2nd 2800mm
diameter jacked
pipeline

Formation of Working Pit

3000
Edge of Sheetpile

Grout Pattern for Treated Soil Block outside

Launching Eye in Jacking Pit
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 Influence Zone of
Grout Spread
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Spacing of Grout
+ +
+ Hole 600mm c/c

Overlapping
Zone

+ + + +

+ + +
Grout Hole

Typical Details of Treated Soil Block

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Rubber Seal Entrance Ring Hydraulic Jack Slurry Pipeline
System

Installation of Entrance Ring Pushing First Can of TBM to

Entrance Ring

Operation in Jacking Pit

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Positioning of TBM
Machine Cans
in Jacking Pit
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Jacking Pipe
• Precast Concrete Pipe with a Strength of 50MPa
• 18mm Thick Soft Wood Packer Provided for Each Pipe
• Grout Holes Provided at Crown Level, and at Axis Level (for Every Fifth
Pipe), for Lubrication and Grouting

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Appearance of Intermediate Jacking Station

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Spoil Handling System

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Sodium-based Bentonite After

Bentonite Mixing

Bentonite Being Pumped

to Jacked Pipeline for
Lubrication

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Automatic Lubrication Station

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Separation of Excavated Materials in Desander

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Appearance of TBM after

being pushed into Receiving Pit
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Intermediate Slurry Pipes and Electric Lifting eye /
Jack Cables Grout Hole

Tunnel Formed by Precast Condition of Completed Tunnel

Concrete Pipes

Tunnel Formed by TBM Pipejacking

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TBM Pipejacking in Triangular Configuration

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EXISTING TREE TO BE
RETAINED
SHEETPILES FOR WORKING PIT

132kV CLP CABLES

RELOCATED WORKING PIT B-3

11kV CLP CABLES

11kV / 132kV 2 x 1500mm dia. pipeline by 2 x 1500mm
CLP CABLES HandShield Pipejacking from dia. TBM
Working Pit B-3 Pipejacking
1 x 1200mm dia. pipeline
to Working
by HandShield Pipejacking
Pit B-1
from Working Pit B-3
400 mm. DIAMETER GAS MAIN WORKING PIT B-2

1200mm dia. TBM

Pipejacking to Working Pit B-1

Jacked Pipeline Arrangement in Working Pit B-2

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1 x 1200mm dia. pipeline by Handshield
Pipejacking
2 x 1500mm dia. pipelines by Handshield
Pipejacking

B-2

B-3
1 x 1200mm dia. pipeline by
TBM
Giant Tree 2 x 1500mm dia. pipelines
by TBM

Giant Tree
B-1

Plan Showing Locations of Working Pits B-1, B-2,

B-3 and the Pipeline Alignment in Between
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Construction of Hand-dug Tunnel from

Receiving Pit

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Original Working Pit
B-1

3 nos. of DN200 DCS

Chilled Water Pipes
with Conc. Surround

Relocated Working
Hand-Dug Tunnel
Hand-dug Tunnel Excavation
Pit B-1 (Receiving
Pit) from Working Pit

A School
Carriageway Planter
Planter Footpath Site
A Telecoms Cables
with Conc. Surround Ground Level

CLP Cables (400kV) Telecoms Cables

With Conc. Surround with Conc. Surround 3 nos. of
DN200
DCS Chilled
CLP Cables (132kV) CLP Cables With Water Pipes
With Conc. Surround Conc. Surround with Conc.
Surround
CLP Cables (11kV)
With Conc. Surround Original
Working Pit
Planter B-1 location

Hand Dug Tunnel

Jacked Pipeline Section A-A

from Working Pit Revised Working Pit B-1 to
Utilities Congested at Original B-2 suit site constraints
Working Pit Location

Location of Working Pit B-1 and Hand-dug Tunnel

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WORKING PIT WORKING PIT

B-1 (RECEIVING PIT) +6.00 mPD +6.00 mPD B-2 (JACKING PIT)

N
N
= 17
N
=7 FILL N
= 30 =9

1 No. TBM PIPEJACKING DN1200

-4.6 mPD -5.59mPD
2 Nos. TBM PIPEJACKING DN1500

N N
N = 45 ALLUVIUM = 45 N
= 32
= 22

N
= 32
N
= 48 CDG N
= 48
N
= 25

Inferred Geological Profile

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Manual Excavation in Upper Bench Lower Bench Excavation in Hand-

of Hand-dug Tunnel dug Tunnel by Mini-excavator

Hand-dug Tunnel Excavation from Receiving Pit

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Hand-dug Tunnel Excavation from Receiving Pit

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Parallel Running of 2 Nos. of 1.5m Diameter TBM

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 Note: 2 nos. of 1500 mm dia. TBM advanced
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GL = 6.00 mPD

Sheetpiles
1.2ɸ
Working Pit B-2
1x 1200mm dia. Hand-
shield Pipejacking
1.5ɸ 1.5ɸ
1x 1200mm dia. Man-shield
Pipejacking X SECTION X-X

1x 1200mm dia. TBM

1000
2x 1500mm dia. Hand-
shield Pipejacking
2x 1500mm dia. TBM
FL = - 5.59 mPD

X
SIDE ELEVATION

Pipejacking in Working Pit B-2

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Parallel Running of 2 nos. of 1.5m Dia. TBM

Pipejacking in Jacking Pit
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TBM Breakthrough in Hand-dug Tunnel

from Receiving Pit
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Lifting Up of TBM from Receiving Pit

to Ground Surface
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Preparation of Receiving Eye for TBM Entry

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Caving Construction in the Lower Portion of

Receiving Pit for Receiving 2.8m Diameter TBM

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 2800mm dia. Pipeline by
Wilson W.S.Caving
Hand-dug Mok TBM from Working Pit B-5

Working Pit B-4

Pipepile
Plan
Construction of Hand-dug Caving in Working Pit B-4
5800

PIPE PILE ROOF

(PIPES AT 0.6m c/c) 254 x 254 x 89kg/m UC
(COLUMN OF PORTAL FRAME)

PIPES AT 0.7m c/c

4500

3400

DN2800 TBM

305 x 305 x 97kg/m UC

GUIDE RAIL BLINDING CONCRETE

Front Elevation of the Caving As-Constructed Caving in Working Pit B-4

Working Pit B-4 - Change of Construction Methodology for

Receiving Tunnel Boring Machine due to Constraints by Existing Utilities
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TBM Entry in Caving of Working Pit B-4

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Skin-off of 2.8m Diameter TBM

for Lifting up to Ground Surface

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TBM Entry in Caving and Skin-off of TBM

at Working Pitp for Lifting up to Ground Surface
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Skin-off of TBM at Working Pit for

Lifting up to Ground Surface
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Installation of DCS Pipelines

in the Completed Jacked Pipelines

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Concrete platform for
placing guide rails
Railing
Tailored made steel trolley for
transportation of DCS pipes in
Pipejacked Tunnel
Railing

Installation of guide rails in Installation of DCS Pipes

Concrete Platform

DCS Pipes Installation in Jacked Pipeline

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DCS Pipelines Installation in Jacked Pipeline

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Problems Commonly Encountered by TBM

Pipejacking
• Alignment Control
• Ground Settlement
• Obstruction
• Damage of Jacking Pipes

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