Bangkok Mass Transit Blue Line Extension Project Specifications

KINGDOM OF THAILAND
MINISTRY OF TRANSPORT
MASS RAPID TRANSIT AUTHORITY OF THAILAND
BLUE LINE EXTENSION PROJECT
CONTRACT 1 : UNDERGROUND CIVIL WORKS
HUA LAMPHONG SANAM CHAI SECTION
TENDER DOCUMENTS
VOLUME 5
OUTLINE CONSTRUCTION SPECIFICATIONS
Bangkok Mass Transit Consultants Consortium
TESCO Ltd. Thai Engineering Consultants Co., Ltd.
MAA Consultants Co., Ltd. IT International Co., Ltd

Chotichinda Mouchel Consultants Limited Norconsult Civil Engineering Co., Ltd.
D2 Consult Asia Co., ltd. Transport East West Expert Team GmbH
December 2009
Volume 5 : Outline Construction Specifications OCS- i
MASS RAPID TRANSIT AUTHORITY OF THAILAND
BLUE LINE EXTENSION PROJECT
CONTRACT 1 : UNDERGROUND CIVIL WORKS
HUA LAMPHONG - SANAM CHAI SECTION
TENDER DOCUMENTS
VOLUME 5
OUTLINE CONSTRUCTION SPECIFICATIONS
CONTENTS
Page
SECTION 1 : STANDARDS
Guidance Note to the Specification ............................................................................................... OCS-2
1.1 Introduction ....................................................................................................................... OCS-2
SECTION 2 : EARTHWORKS
2.1 Excavation ........................................................................................................................ OCS-9
2.2 Fill ................................................................................................................................... OCS-11
2.3 Tests ............................................................................................................................... OCS-14
2.4 Landscaping ................................................................................................................... OCS-15
SECTION 3 : ROADWORKS
3.1 Subbase ......................................................................................................................... OCS-17
3.2 Aggregate Base .............................................................................................................. OCS-18
3.3 Asphaltic Materials ........................................................................................................ OCS-20
3.4 Asphaltic Prime Coat ...................................................................................................... OCS-24
3.5 Asphaltic Tack Coat........................................................................................................ OCS-25
3.6 Asphaltic Surface Treatment .......................................................................................... OCS-25
3.7 Asphaltic Concrete Surfacing ......................................................................................... OCS-29
3.8 Reinforced Concrete Pavement ..................................................................................... OCS-38
3.9 Co-ordination with Highway Agencies ............................................................................ OCS-55
3.10 Road Marking, Traffic Signs and Traffic Signals ............................................................ OCS-55
SECTION 4 : PILING AND DIAPHRAGM WALLING

4.1 General ........................................................................................................................... OCS-58
4.2 Concrete Piles ................................................................................................................ OCS-59
4.3 Precast Concrete Piles ................................................................................................... OCS-60
4.4 Cast in Place Piles.......................................................................................................... OCS-61
4.5 Pile Testing ..................................................................................................................... OCS-63
4.6 Diaphragm Walling ........................................................................................................ OCS-76
CONTRACT 1 Dec. 09
Volume 5 : Outline Construction Specifications OCS- ii
CONTENTS (Contd.)
Page
SECTION 5 : CONCRETE
5.1 Concrete Materials ......................................................................................................... OCS-82
5.2 Concrete Workmanship .................................................................................................. OCS-88
5.3 Precast Concrete ......................................................................................................... OCS-103
SECTION 6: PRESTRESSED MEMBERS

6.1 Prestressing Tendons .................................................................................................. OCS-108
6.2 Precast Construction ................................................................................................... OCS-109
6.3 Stressing Tendons........................................................................................................ OCS-109
6.4 Testing by Contractor ................................................................................................... OCS-110
6.5 Pretensioning ................................................................................................................ OCS-111
6.6 Post-tensioning ............................................................................................................. OCS-111
6.7 Prestressing Tendons - Protection and Bond .............................................................. OCS-112
6.8 Ducts for Bonded Tendons ........................................................................................... OCS-113
6.9 Ducts for Unbonded Tendons ...................................................................................... OCS-115
6.10 Prestressing Tendons - Trial Construction-Unbonded Tendons .................................. OCS-116
6.11 Prestressing Tendons - Temporary Tendons .............................................................. OCS-116
6.12 Preparation for Casting................................................................................................. OCS-116
SECTION 7 : STRUCTURAL STEELWORK

7.1 General ........................................................................................................................ OCS-120
7.2 Material properties ....................................................................................................... OCS-120
7.3 Testing ......................................................................................................................... OCS-120
7.4 Fabrication .................................................................................................................. OCS-120
7.5 Detailing of connections .............................................................................................. OCS-120
7.6 Submissions ................................................................................................................. OCS-121
7.7 Welding ......................................................................................................................... OCS-121
7.8 Electrodes .................................................................................................................... OCS-121
7.9 Welders......................................................................................................................... OCS-121
7.10 Testing ......................................................................................................................... OCS-121
7.11 Site welding .................................................................................................................. OCS-121
7.12 Erection of steelwork .................................................................................................... OCS-122
7.13 Tolerances .................................................................................................................... OCS-122
7.14 Bolted connections ....................................................................................................... OCS-122
7.15 Transportation and storage .......................................................................................... OCS-122
7.16 Damaged material ........................................................................................................ OCS-122
7.17 Galvanising ................................................................................................................... OCS-122
7.18 Preparation of steelwork for protective treatment ........................................................ OCS-123
7.19 Painting generally ......................................................................................................... OCS-123
CONTRACT 1 Dec. 09
Volume 5 : Outline Construction Specifications OCS- iii
CONTENTS (Contd.)
Page
7.20 Application of protective layers .................................................................................... OCS-124

7.21 Protection of bolts etc. .................................................................................................. OCS-124
7.22 High strength friction grip connections ......................................................................... OCS-124
7.23 Protective treatment ..................................................................................................... OCS-124
7.24 Paintwork executed on site .......................................................................................... OCS-124
SECTION 8 : ARCHITECTURAL AND BUILDING WORKS

8.1 General Requirements ................................................................................................. OCS-129
8.2 Brickwork & Blockwork ................................................................................................. OCS-129
8.3 Pavior............................................................................................................................ OCS-132
8.4 Roofer ........................................................................................................................... OCS-140
8.5 Carpenter and Joiner .................................................................................................... OCS-146
8.6 Steel and Metal Worker ................................................................................................ OCS-151
8.7 Plasterer and Tiler ........................................................................................................ OCS-176
8.8 Plumber ........................................................................................................................ OCS-179
8.9 Glazier .......................................................................................................................... OCS-181
8.10 Painter .......................................................................................................................... OCS-185
8.11 Signmaker .................................................................................................................... OCS-190
8.12 Ironmongery ................................................................................................................. OCS-198
SECTION 9 : TUNNELLING
9.1 Introduction .................................................................................................................. OCS-207
9.2 General ........................................................................................................................ OCS-207
9.3 Excavation ................................................................................................................... OCS-207
9.4 Segmental Tunnel Linings ........................................................................................... OCS-210
9.5 Spheroidal Graphite Iron Lining (SGI Lining) .............................................................. OCS-213
9.6 Precast Concrete Linings ............................................................................................ OCS-218
9.7 Alternative Tunnel Lining ............................................................................................. OCS-220
9.8 Grouting ....................................................................................................................... OCS-220
9.9 Watertightness of Tunnel ............................................................................................ OCS-223
9.10 Pilot Tunnels ................................................................................................................ OCS-223
9.11 Daily Records .............................................................................................................. OCS-223
9.12 Geological Record ....................................................................................................... OCS-223
9.13 Backfilling of Shafts and Adits ..................................................................................... OCS-223
9.14 Working Under Compressed Air .................................................................................. OCS-223
9.15 Minimum Requirements of Tunnel Boring Machine (TBM) .......................................... OCS-225
CONTRACT 1 Dec. 09
Volume 5 : Outline Construction Specifications OCS- iv
CONTENTS (Contd.)
Page
SECTION 10 : CUT AND COVER CONSTRUCTION
10.1 General ........................................................................................................................ OCS-228
10.2 Liquid-Applied Elastomeric Waterproofing Membrane ................................................. OCS-228
SECTION 11 : SOIL IMPROVEMENT WORKS

11.1 General ......................................................................................................................... OCS-232
11.2 Soil Improvement Using Jet Grouting........................................................................... OCS-232
11.3 Soil Improvement Using Freezing ................................................................................ OCS-235
SECTION 12 : INSTRUMENTATION
12.1 Introduction ................................................................................................................... OCS-238
12.2 Instrumentation Requirements ..................................................................................... OCS-238
12.3 Monitoring Plans and Related Documents ................................................................... OCS-238
12.4 Minimum Monitoring ..................................................................................................... OCS-240
12.5 Instrument Types and Requirements ........................................................................... OCS-250
12.6 Instrumentation Records and Reports .......................................................................... OCS-262
SECTION 13 : NATM SPECIFICATIONS

13.1 General ......................................................................................................................... OCS-264
13.2 Geotechnical Investigations .......................................................................................... OCS-265
13.3 Jet Grouting and Injections ........................................................................................... OCS-269
13.4 Support Measures ....................................................................................................... OCS-273
13.5 Geotechnical Measurements ........................................................................................ OCS-280
13.6 Inner Lining ................................................................................................................... OCS-292
CONTRACT 1 Dec. 09
Volume 5 : Outline Construction Specifications OCS- v
LIST OF GENERAL ABBREVIATIONS
Note: International metric measurement units are not listed.

Some additional specialist abbreviations are defined in the relevant section of the documents.
AASHTO American Association of State Highway and Transportation Officials

AC Alternating Current
ACI American Concrete Institute
AFC Automatic Fare Collection
ANSI American National Standards Institute
API American Petroleum Industry
AREA American Railway Engineering Association
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
ATO Automatic Train Operation
ATP Automatic Train Protection
ATS Automatic Train Supervisory System
BMA Bangkok Metropolitan Administration

BE Blue Line Extension
BS British Standard
CAT CAT Telecom Public Company Limited

CBR California Bearing Ratio
CCTV Closed Circuit Television
CIP Co-ordinated Installation Plan
CMS Control and Monitoring System
CPM Critical Path Method
CSD Combined Serviced Drawings
CWR Continuously Welded Rail
DC Direct Current
DFIS Diagnostic and Fault Indicating System
DIN Deutsche Industrie Normen
DOH Department of Highways
DSD Drivers Safety Device
ECS Environmental Control System

EGAT Electricity Generating Authority of Thailand
EMC Electromagnetic Compatibility
EMU Electric Multiple Unit
EN Euronorm Standard
EOT Electric Overhead Traveling (crane)
FAP Fire Alarm Panel

GCC General Conditions of Contract
HV High Voltage
CONTRACT 1 Dec. 09
Volume 5 : Outline Construction Specifications OCS- vi
ID Identification
IEC International Electrotechnical Commission
IEE Institution of Electrical Engineers
IEEE Institute of Electrical and Electronic Engineers
IES Illumination Engineering Society (UK)
ISO International Standards Organization
ISP Initial System Project
JIS Japanese Industrial Standards
KD Key Date
LV Low Voltage
MEA Metropolitan Electricity Authority

MPR Monthly Progress Report
MRTA Mass Rapid Transit Authority of Thailand
MSL Mean Sea Level
MWA Metropolitan Waterworks Authority
NC Noise Criterion
NEC National Electrical Code
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
No. Number
O&M Operations and Maintenance

OTP Office of Transport and Traffic Policy and Planning
PA Public Address
PDM Precedence Diagramming Method
PID Passenger Information Display
SCADA Supervisory Control and Data Acquisition

SE System Earth
SI International System
SOR Station Operations Room
TIS Thai Industrial Standard
TOT TOT Public Company Limited
TSP Thai Standards on Pollution
TVM Ticket Vending Machine
UIC International Union of Railways
UPS Uninterruptible Power Supply
VDE Verband Deutsche Elektrotechinke
VDU Visual Display Unit
WAHD Works Area Handover Date
WC Water Closet (toilet)
CONTRACT 1 Dec. 09
Volume 5 Outline Construction Specifications OCS- 1
1 Section 2 Earthworks
To be completed by the Contractor
2 Section 3 Roadworks
3 Section 4 Piling and Diaphragm Walling
4 Section 5 Concrete
5 Section 6 Precast Concrete
6 Section 7 Structural Steelwork
7 Section 8 Architectural and Building Works
8 Section 9 Tunnelling
9 Section 10 Cut and Cover Construction
CONTRACT 1 Dec. 09
GUIDANCE NOTE TO THE SPECIFICATION
1.1 INTRODUCTION
The Materials and Workmanship Specification as follows has been based on International
Standards as scheduled below. The Contractor will be responsible for detailing in his
specification the standards on which his materials and workmanship will be based, and these
will be of similar or higher standard than those listed below:
The Contractor is required to review in the first instance the Thai Industrial Standards and
the specification will be based on Thai Industrial Standards to the extent that they are
applicable.
Section 2 Earthworks
AASHTO T99 The Moisture-Density Relations of Soils using a 5.5lb (2.5kg)
Rammer and a 12in (305mm) Drop.
AASHTO T180 The Moisture-Density Relations of Soils using a 10lb (4.54kg)
Rammer and a 18in (457mm) Drop.
AASHTO T191 In-situ Density by Sand Replacement.
AASHTO T205 Density of Soil In-Place by the Rubber-Balloon Method.
AASHTO T238 Density of Soil and Soil Aggregate In-Place by Nuclear Methods
(Shallow Depth).
ASTM D1556 In-situ Density by Sand Replacement.
BS 1377 Methods of testing soils for civil engineering purposes.
Section 3 Roadworks
Department of Highways Specifications for Highway Construction.

DH-S Standard for Highway Construction
DH-T Standard Testing
DH-SP Specification for Materials
Section 4 Piling
TIS 395-2524 Standard for Precast Reinforced Concrete Piles

TIS 399-2524 Standard for Precast Reinforced Concrete Short Piles
TIS 397-2524 Standard for Precast Reinforced Spun Concrete Piles
TIS 396-2524 Standard for Prestressed Concrete Piles
TIS 398-2537 Standard for Prestressed Spun Concrete Piles
AASHTO Standard Spec. for Highway Bridges
ASTM D4945 Test Method for High Strain Dynamic Testing of Piles
ASTM D1143 Test Method for Piles Under Static Axial Compression Load
ASTM D3689 Test Method of Testing Individual Piles Under Static Axial Tensile Load
ASTM D3966 Method of Testing Piles Under Lateral Loads
ACI-543 R-74 (80) Recommendation for Design, Manufacture and Installation of
Concrete Piles
ACI 336-1-89 Standard Specification for the Construction of Drilled Piers
CONTRACT 1 Dec. 09
Section 5 Concrete
TIS 15 Portland Cement.

TIS 20 Reinforcing bar, Round Bar.
TIS 24 High Yield Deformed Bars.
TIS 138 Standard of Binding Wire.
AASHTO Standard Specification for Highway Bridges
AASHTO M6 Fine Aggregate.
AASHTO M80 Coarse Aggregate.
AASHTO M194 Admixtures.
AASHTO T26 Quality of Water to be used in Concrete.
ACI 305 Recommendations for Hot Weather Concreting.
ASTM C39 Method of Test for Compressive Strength of Moulded Concrete
Cylinders.
ASTM C232 Method of Test for Bleeding of Concrete.
BS 639 Covered carbon and carbon manganese steel electrodes for metal-
arc welding.
BS 812 Testing Aggregates.
BS 882 Aggregates from natural sources for concrete.
BS 1014 Pigments for Portland cement and Portland cement products.
BS 1610 Materials testing machines and force verification equipment.
BS 1881 Methods of testing concrete.
BS 3148 Water for making concrete.
BS 3797 Lightweight aggregates for concrete.
BS 4466 Scheduling, dimensioning, bending and cutting for steel
reinforcement for concrete.
BS 4550 Methods of testing cement.
BS 5075 Concrete admixtures.
BS 5135 Process of arc welding of carbon and carbon manganese steel.
BS 5328 Methods for specifying concrete, including ready mixed concrete.
BS 5400 Part 4 Code of practice for the design of concrete bridges.
BS 5606 Accuracy in building.
BS 8110 Structural use of concrete.
Section 6 Precast Concrete
TIS 420 Standard for uncoated 7 wire stress relieved strand for prestressed
concrete.
AASHTO Standard Specification for Highway Bridges
BS 1881 Methods of testing concrete.
BS 4360 Weldable structural steels.
BS 4447 The performance of prestressing anchorages for post-tensioned
construction
BS 4486 Hot rolled and hot rolled and processed high tensile alloy steel bars
for pretensioning of concrete.
CONTRACT 1 Dec. 09
BS 5896 High tensile steel wire and stand for the prestressing of concrete.
BS 8301 Section 5. Code of practice for building drainage.
Section 7 Structural Steelwork
TIS 49 Covered electrodes for arc welding of mild steel.

AASHTO Standard Specification for Highway Bridges American Petroleum
Industry (API) Standard 1104
BS 639 Covered carbon and carbon manganese steel electrodes for manual
arc-welding.
BS 729 Hot dipped galvanised coatings on iron and steel articles.
BS 970 Wrought steels for mechanical and allied engineering purposes.
BS 2989 Continuously hot-dip zinc coated and iron-zinc alloy coated steel flat
products: Tolerances on dimensions and shape.
BS 3083 Hot-dip zinc coated and hot-dip aluminium/zinc coated corrugated
steel sheets for general purposes.
BS 4190 ISO metric black hexagon bolts, screws and nuts.
BS 4320 Metal washers for general engineering purposes.
BS 4395: Part 2 High strength friction grip bolts and associated nuts and washers for
Structural Engineering. Higher Grade.
BS 4604: Part 2 The use of high strength friction grip bolts in structural steelwork.
Higher grade (parallel shank).
BS 4870 Approval testing of welding procedures.
BS 4871 Approval testing of welders working to approved welding procedures.
BS 4872 Approval testing of welders when welding procedure approval is not
required.
BS 5135 Process of arc welding of carbon and carbon manganese steels.
BS 5400: Part 6 Specification for materials and workmanship, steel.
BS 5950: Part 2 Specification for materials, fabrication and erection: hot rolled
sections
BS 6105 Corrosion-resistant stainless steel fasteners.
BS 6443 Penetrant flaw detection.
BS 7079 Preparation of steel substrates before application of paints and
related products.
Section 8 Architectural and Building Works
NFPA 101 Life safety code

NFPA 130 Standard for fixed guideway transit and passenger rail systems
NFPA 220 Standard on types of building construction
LUL E1042:A4 Engineering standard for the fire safety performance of materials
used underground
ASTM C 39 Standard test method for compressive strength of cylindrical
concrete specimens
ASTM C 232 Standard test methods for bleeding of concrete
BS 405 Specification for uncoated expanded metal carbon steel sheets for
general purposes
CONTRACT 1 Dec. 09
BS 416: Part 1 Discharge and ventilating pipes and fittings, sand-cast or spun in
cast iron. Specification for spigot and socket systems.
BS 460 Cast iron rainwater goods. Specification.
BS 476: Part 3 Fire tests on building materials and structures. Classification and
method of test for external fire exposure to roofs
BS 476: Part 6 Fire tests on building materials and structures. Method of test for fire
propagation for products
BS 476: Part 7 Fire tests on building materials and structures. Method of test to
determine the classification of the surface spread of flame of
products
BS 476: Part 20 Fire tests on building materials and structures. Method for
determination of the fire resistance of elements of construction
(general principles)
BS 476: Part 22 Fire tests on building materials and structures. Methods for
determination of the fire resistance of non-loadbearing elements of
construction.
BS 812 Testing aggregates. Guide to sampling and testing aggregates.
BS 890 Specification for building limes
BS 952 Glass for glazing
BS 1014 Specification for pigments for Portland cement and Portland cement
products
BS 1161 Specification for aluminium alloy sections for structural purposes
BS 1191 Specification for gypsum building plasters.
BS 1199/1200 Specifications for building sands from natural sources
BS 1336 Specification for knotting
BS 1369 Steel lathing for internal plastering and external rendering.
Specification for expanded metal and ribbed lathing.
BS 1387 Specification for screwed and socketed steel tubes and tubulars.
BS 1449 Steel plate, sheet and strip.
BS 1474 Specification for wrought aluminium and aluminium alloys for general
engineering purposes: bars, extruded round tubes and sections
BS 1494 Specification for fixing accessories for building purposes. Fixings for
sheet, roof and wall coverings.
BS 1723 Brazing.
BS-2750 /ISO 140 Acoustics.
BS 2871 Specification for copper and copper alloys. Tubes.
BS 3416 Specification for bitumen based coatings for cold application, suitable
for use in contact with potable water
BS 3638 Method for the measurement of sound absorption coefficients (ISO)
in a reverberation room
BS 3987 Specification for anodic oxidation coatings on wrought aluminium for
external architectural applications
BS 4255 Rubber used in preformed gaskets for weather exclusion from
buildings. Specification for non-cellular gaskets.
BS 4641 Method for specifying electroplated coatings of chromium for
engineering purposes
BS 4772 Specification for ductile iron pipes and fittings
CONTRACT 1 Dec. 09
BS 4800 Schedule of paint colours for building purposes

BS 4887 Specification for mortar plasticizers
BS 4921 Specification for sherardized coatings on iron and steel
BS 5385 Wall and floor tiling, code of practice for the design and installation of
terrazzo tile and slab, natural stone and composition block floorings
BS 5427: Part 1 Code of practice for the use of profiled sheet for roof and wall
cladding on buildings.
BS 5628 Code of Practice for use of masonry, Materials and components,
design and workmanship
BS 5810 Code of practice for access for the disabled to buildings
BS 5980 Specification for adhesives for use with ceramic tiles and mosaics
BS 6180 Barriers in and about buildings. Code of practice.
BS 6202 Specification for impact performance requirements for flat safety
glass and safety plastics for use in buildings
BS 6213 Selection of construction sealants. Guide.
BS 6229 Flat roofs with continuously supported coverings. Code of practice.
BS 6262 Glazing for buildings.
BS 6399 Loading for buildings
BS 6431 Ceramic floor and wall tiles. Specification for classification and
marking, including definitions and characteristics.
BS 6459: Part 1 Door closers. Specification for mechanical performance of crank and
rack and pinion overhead closers.
BS 6477 Specification for water repellents for masonry surfaces
BS 6496 Specification for powder organic coatings for application and stoving
to aluminium alloy extrusions, sheet and preformed sections for
external architectural purposes, and for the finish on aluminium alloy
extrusions, sheet and preformed sections coated with powder
organic coatings
BS 7352 Specification for strength and durability performance of metal hinges
for side hanging applications and dimensional requirements for
template drilled hinges.
BS 7668 Weldable structural steels. Hot finished structural hollow sections in
weather resistant steels. Specification.
BS 8204: Part 1 Screeds, bases and in-situ floorings. Code of practice for concrete
bases and screeds to receive in-situ floorings.
BS 8217 Reinforced bitumen membranes for roofing. Code of practice.
BS 8218 Code of practice for mastic asphalt roofing.
BS 8290 Suspended ceilings.
BS 8298 Code of practice for design and installation of natural stone cladding
and lining
BS EN 485: pts 1-4 Aluminium and aluminium alloys. Sheet, strip and plate.
BS EN 515 Aluminium and aluminium alloys. Wrought products.
BS EN 573 Aluminium and aluminium alloys. Chemical composition and form of
wrought products.
BS EN 1125 Building hardware. Panic exit devices operated by a horizontal bar.
Requirements and test methods.
CONTRACT 1 Dec. 09
BS EN ISO 1461 Hot dip galvanized coatings on iron and steel articles. Specifications
and Methods
BS EN 10029 Specifications for tolerances on dimensions, shape and mass for hot
rolled steel plates 3mm thick or above.
BS EN 10088 Stainless steels.
BS EN 10258 Cold-rolled stainless steel narrow strip and cut lengths. Tolerances
on dimensions and shape.
BS EN 10259 Cold-rolled stainless and heat resisting steel wide strip and
plate/sheet. Tolerances on dimensions and shape.
BS EN 12206-1 Paints and varnishes. Coating of aluminium and aluminum alloys for
architectural purposes. Coatings prepared from coating powder.
Section 9 Tunnelling
BS 21 Specification for pipe threads for tubes and fittings where pressure-
tight joints are made on the threads.
BS 143 Specification for malleable cast iron and cast copper alloy threaded
pipe fittings.
BS 729 Specification for hot dip galvanised coatings on iron and steel
articles.
BS 1134 Method for the assessment of surface texture.
BS 2789 Specification for spheroidal graphite or nodular graphite cast iron.
BS 2494 Elastomeric seals for joints in pipework and pipelines.
BS 5400 Steel, concrete and composite bridges.
BS 6164 Safety in Tunnelling in the construction industry.
BS 6681 Specification for malleable cast iron.
CIRIA Report 80 A review of instruments for gas and dust monitoring underground.
CIRIA Report 81 Tunnel Waterproofing.
CIRIA Report 44 Medical Code of Practice for work in Compressed Air.
CONTRACT 1 Dec. 09
SECTION 9: TUNNELLING
Page
9.1 Introduction OCS-224
9.2 General OCS-224
9.3 Excavation OCS-224
9.3.1 General OCS-224

9.3.2 Break-outs for Openings, Junctions and Similar Structures OCS-225
9.3.3 Excavation by Hand OCS-225
9.3.4 Excavation with Care OCS-225
9.3.5 Control of Excavation OCS-226
9.3.6 Overbreak OCS-226
9.3.7 Earlier Investigation Holes OCS-226
9.3.8 Probing OCS-226
9.3.9 Dealing with Water OCS-227
9.3.10 Excavation Close to Completed Tunnel Works OCS-227
9.3.11 Enlargements OCS-227
9.3.12 Surveying OCS-228
9.4 Segmental Tunnel Linings OCS-228
9.4.1 Design OCS-228

9.4.2 Trial Assembly OCS-228
9.4.3 Marking of Tunnel Segments OCS-228
9.4.4 Transporting and Storing Segments OCS-229
9.4.5 Joints OCS-229
9.4.6 Rolled Rings OCS-229
9.4.7 Bolts OCS-229
9.4.8 Plane OCS-229
9.4.9 Sealing Strips OCS-229
9.4.10 Caulking Grooves OCS-230
9.4.11 Grout Valves OCS-230
9.4.12 As-built Tolerances OCS-230
9.4.13 Non-Compliance with Tolerances OCS-231
9.4.14 Damaged Segments OCS-231
9.5 Spheroidal Graphite Iron Lining (SGI Lining) Cast iron OCS-231
9.5.1 Quality of Materials and Castings OCS-231

9.5.2 Testing OCS-231
9.5.3 Machining, Drilling and Bolting OCS-233
9.5.4 Tolerances OCS-233
9.5.5 Painting and Protective Coatings OCS-234
9.5.6 Caulking OCS-235
9.5.7 Grout Holes OCS-235
9.5.8 Grout Plugs OCS-236
CONTRACT 1 Dec. 09
Page
9.6 Precast Concrete Linings OCS-218

9.6.1 General OCS-218
9.6.2 Materials OCS-218
9.6.3 Connections OCS-218
9.6.4 Moulds OCS-218
9.6.5 Filling of Moulds OCS-219
9.6.6 Grout Holes OCS-219
9.6.7 Tolerances OCS-219
9.6.8 Joints OCS-219
9.6.9 Casting, and Curing OCS-219
9.6.10 Concrete Cover OCS-219
9.6.11 De-Moulding OCS-220
9.6.12 Handling and Stacking OCS-220
9.7 Alternative Tunnel Lining OCS-220
9.8 Grouting OCS-220
9.8.1 Definitions OCS-220

9.8.2 Method OCS-220
9.8.3 Mix OCS-221
9.8.4 Injection OCS-221
9.8.5 Grout Plugs OCS-221
9.8.6 Records OCS-221
9.8.7 Monitoring Pressures OCS-221
9.8.9 Shafts OCS-221
9.8.10 In-situ Linings and Junctions OCS-222
9.8.11 Performance OCS-222
9.8.12 Verification OCS-222
9.9 Watertightness of Tunnel OCS-223
9.10 Pilot Tunnels OCS-223
9.11 Daily Records OCS-223
9.12 Geological Record OCS-223
9.13 Backfilling of Shafts and Adits OCS-223
9.14 Working Under Compressed Air OCS-223
9.14.1 Medical Aspects of Work in Compressed Air OCS-223
9.14.2 Use of Compressed Air OCS-224
9.14.3 Compressed Air Retaining Installations OCS-224
9.14.4 Plant OCS-224
9.14.5 Locks OCS-225
9.14.6 Pressure Control OCS-225
9.14.7 Pressure Gauges OCS-225
9.14.8 Telephones OCS-225
9.14.9 Layout OCS-225
9.14.10 Identity Cards OCS-225
9.14.11 Records OCS-225
9.15 Minimum Requirements of Tunnel Boring Machine (TBM) OCS-225
CONTRACT 1 Dec. 09
SECTION 9: TUNNELLING
9.1 Introduction
This section specifies materials methods and workmanship required for the construction
of tunnels, headings, adits, shafts and junctions.
9.2 General
(a) All works shall be carried out in compliance with the Health and Safety
requirements as detailed in the Employer's Requirements.
(b) All aspects of excavation in tunnels shall comply with the requirements of:
BS 6164 Safety in Tunnelling in the Construction Industry
CIRIA Report A review of instruments for gas and dust monitoring
underground. (R080M)
(c) For requirements of work in compressed air see Clause 9.14.
(d) Where tunnels are excavated by means of a Tunnel Boring Machine or other
mechanical means, details of such means, including manufacturer's drawings,
and methods of working shall be submitted as part of the Design Submission.
9.3 Excavation
9.3.1 General
(a) Except where otherwise specified in this Section of the Specification, all
excavations in tunnels, shafts and junctions shall also comply with the
requirements of Section 2 - Earthworks, and shall conform to the dimensions
shown on the consented-to drawings.
(b) Prior to commencing excavation for temporary or permanent works, the
Contractor shall prepare appropriate designs, drawings and method statements
relating to his proposed methods of working. Such methods shall ensure that
there is no damage to or deterioration of the final surfaces of the excavations and
ensure that surface settlement and distortion to underground structures are kept
to acceptable limits.
(c) No pedestrian access along the tunnel track way shall be permitted while
haulage operations are in progress. Segregated pedestrian access should be
provided where appropriate.
(d) The exhaust systems of any internal combustion vehicles used underground shall
be fitted with air cleaning equipment.
(e) The safety and security of all excavations, either surface or underground, shall, at
all times during the construction, be the responsibility of the Contractor. The
Contractor shall implement such measures, including supporting, stanching,
dewatering and consolidation, as may be necessary to fulfill this obligation.
The design of temporary works and ground supports, particularly those for
locations below rivers, railways and highways should be verified as required
under the Contractor's Quality Plan.
(f) All inclined tunnel drives shall have runaway vehicle protection.
(g) The Contractor shall construct the Works in such a way that the settlement
effects are kept within the specified limits.
The Contractor shall take such consented-to measures as may be necessary to
ensure that damage to structures resulting from ground movements is no greater
than Degree 'Slight' as defined in the Outline Design Specification.
CONTRACT 1 Dec. 09
Such measures might include:

a) special tunnelling methods to reduce ground loss;
b) protection measures such as:
underpinning
ground improvement
compensation grouting
structural jacking
structural strengthening
curtain walling
9.3.2 Break-outs for Openings, Junctions and Similar Structures
The methods used for the excavation of break-outs (also break-outs through e.g.
diaphragm walls for TBM start or arrival) shall be appropriate to their size and prevailing
ground conditions. Detailed drawings shall be prepared of ground support, propping and
strutting and other aspects of construction and temporary support measures. These shall
be submitted to the Employer's Representative together with the construction procedures
prior to commencement of the work. Particular care shall be taken to avoid damage to the
structures from which breaking out is taking place. Adequate support measures shall be
applied to distribute the force due to the opening..
9.3.3 Excavation by Hand
Excavation by hand shall be carried out to the required profiles, keeping overbreak to a
minimum. The maximum length to be excavated and supported shall be 1 ring widths
during tunnel driving. However, in special circumstances a greater length may be
excavated for two-ring break-ups or similar.
9.3.4 Excavation with Care
All necessary precautions shall be taken in order to prevent softening or deterioration of

excavation surfaces through exposure.
(a) Where necessary to ensure the safety and security of the Works, excavation for
underground Works shall be continuous by day and night. The Contractor's
procedures may allow intermissions at weekends and general holidays, providing
the Works are safe and are inspected by the Contractor at appropriate intervals.
(b) Where open faced tunnelling is to be carried out, the Contractor shall provide
adequate means to support the face in an emergency. The support system shall
be maintained in good order at all times and if not part of the tunnelling shield it
shall be stored as close to the face as is practicable. A detailed drawing of the
support system shall be available close to the tunnel face for reference.
(c) Temporary support will be required to the face at all times during hand
excavation. The type of support provided must suit the actual and anticipated ground
conditions. The ground must be carefully trimmed in order that the supports can
bear fully onto the face with a minimum of wedging.
(d) Where the excavation is to be discontinued for any period of time the face must
be supported in such a manner that ground movement is prevented.
In general, the Contractor shall at all times carry out excavation to the Works such that
the minimum of ground movement is allowed to take place.
CONTRACT 1 Dec. 09
9.3.5 Control of Excavation
(a) Excavation shall be carried out in a uniform controlled manner.

(b) Overcutting shall be kept to a minimum practicable consistent with the need to
maintain the least necessary clearance around the tunnel boring machine.
9.3.6 Overbreak
Should the excavation extend beyond the excavation lines shown on the consented-to
Drawings such excess excavation shall be filled as necessary with cement grout,
concrete, shotcrete or other durable material as quickly as practicable to minimise ground
movement.
9.3.7 Earlier Investigation Holes
(a) Attention is drawn to the likelihood of intercepting earlier investigation holes

during the tunnel drives. The holes may or may not have been effectively sealed
and represent sources of ingress of water and the like where they emerge in
tunnels. All practical steps necessary shall be taken to identify and seal or plug
any voids found in earlier investigation holes before erecting tunnel linings.
(b) Locations of boreholes carried out by the Employer are given in the Geotechnical
Investigation Report. Information from earlier boreholes, carried out by others, is
indicated on drawings included in Information Provided.
9.3.8 Probing
(a) In areas with open face excavation, in areas of ground treatment or changing
geology and where the mode of excavation is changing (e.g. to TBM in open face
mode), the Contractor shall probe ahead of the face to investigate and prove the
ground to be encountered and to search for water sources. Excavation of the
face shall not proceed without such probing. Probing shall be carried out in the
presence of a qualified Geotechnical Engineer.
(b) The Contractor shall prepare a plan for the probing operation, including a method
statement and information on length of probes, frequency, method and
equipment to be used. When probing is to be carried out, the Contractor shall
provide 24 hours advance notice in case the Employer's Representative wishes
to monitor the operation.
(c) The Contractor shall supply to the Employer's Representative a detailed record of
the ground recorded from the probing holes, a copy of which shall also be kept at
the face. The records shall include the following:
(i) the location, orientation and drilled length of each probe hole;
(ii) a plot of the rate of drill penetration against drilled length;
(iii) the location, nature and quantity of any water inflows;
(iv) the location and extent of any changes in strata.
(d) The number of probe holes, location and orientation and their distance ahead of
the face and outside the extrados of the tunnel shall be governed by the type of
ground anticipated and the excavation method.
(e) Probing shall be repeated and overlapped such that at all times two probe holes
are ahead of the face by a suitable distance. This distance will preferably be at the
maximum weekly tunnel advance, but not less than 20 m.
(f) Probe holes shall be at least 50mm in diameter and a minimum of two in the upper
part of the face shall be raked such that at their extremity, they shall protrude
outside the extrados of the tunnel by at least one tunnel diameter.
CONTRACT 1 Dec. 09
(g) The probe holes shall be grouted with cement grout at a pressure dependent
upon soil conditions overburden, using appropriate grout mixes and grouting
methods.. Grout pressures and flows shall be controlled to avoid exceeding
overburden pressure or causing unacceptable heave or other damage to nearby
utilities or property.
(h) In the vicinity of a geological interface the Contractor shall propose and carry out
additional probing to accurately determine its location and nature.
9.3.9 Dealing with Water
In water bearing ground, water ingress into the Works shall be controlled by chemical
consolidation, ground freezing, compressed air, or other means subject to the consent of
the Employer's Representative.
9.3.10 Excavation Close to Completed Tunnel Works
The Contractor shall ensure in his proposed method of work that any loading that may be
applied to already completed tunnel linings can be safely sustained. In his method
statement and Quality Plan, the Contractor shall give full details of his proposed
construction methods and of temporary propping to withstand the construction loads to be
expected, and any other temporary measures required.
9.3.11 Enlargements
In the design and construction of the temporary works to support the existing tunnels in
the vicinity of enlargements the Contractor shall take into account the following as are
relevant:
(i) The shape of existing tunnels shall be maintained at all times.

(ii) The maximum unsupported length of existing tunnels shall be not greater than
1.5m.
(iii) Invert concreting shall be carried out as appropriate to the consented-to
construction method.
9.3.12 Surveying
Before commencement of work the Contractor shall establish the system for surveying,
setting out and correcting deviations, using a laser based system or approved alternative
methods. Gates and targets shall be used in conjunction with lasers to ensure the
accuracy of the system. Laser based guidance systems shall have an alternative system
as back-up.
9.4 Segmental Tunnel Linings
9.4.1 Design
The segments shall be designed to ensure that the full design life is achieved. In the case
of precast concrete linings, special care shall be taken to ensure that corrosion of
reinforcement or other cast in metal components does not affect the durability of the
segments. Notwithstanding the requirements of Clause 20.8 of the Outline Design
Specification, the design shall assume that the tunnel waterproofing measures will not be
completely effective and therefore allowance shall be made for the effect of groundwater
on any face of a segment.
9.4.2 Trial Assembly
There shall be a trial assembly, before commencement of the bulk manufacture, of three
complete rings bolted together on a horizontal plane platform to demonstrate compliance with
this Specification of rings of each selected material and diameter. The rings shall be built one
CONTRACT 1 Dec. 09
above the other with the cross joints offset by half a segment as appropriate except for
expanded linings. The fully bolted bottom ring shall be bolted to the platform or otherwise
secured in position and shall be retained as a reference master ring until the completion of
tunnel construction. From time to time, as may be required, segments shall be built to form
two rings on the master ring to ensure that tolerances and interchangeability of the segments
are maintained. Adequate notice of the trial assembly shall be given to the Employer's
Representative to enable him to arrange inspection of the whole assembly process.
9.4.3 Marking of Tunnel Segments
(a) All tunnel segments delivered to site shall bear the indelible marks described in (c)
below. Any segment which is delivered to site, upon which the markings cannot be
read for whatever reason, shall not be used in the Works.
(b) The markings must in no way compromise any requirement of this Specification,
i.e.: cover to reinforcement or waterproofing.
(c) The following minimum information, in English, shall be included on the marking:
(i) Internal diameter
(ii) Type of segment: `O` ordinary
`T` top (the T shall be put near the key end of the
segment)
`X` special or taper
For special or tapered rings each segment type shall be marked at each
end to ensure the segments shall be built in the correct sequence and
orientation.
(iii) Mark of the Manufacturer
(iv) Date of Casting and Mark with figures not less than 50 mm high
identifying the casting with the appropriate sample
(v) A Client identifying code and any other information the Employer's
Representative may require.
9.4.4 Transporting and Storing Segments
Segments shall be transported face up with timber spacers. When stored on site
segments shall be stacked on edge, on a prepared level base with timber packing as
necessary. Segments shall be marked to permit easy identification of the different types.
Segments shall not be transported to site until they have achieved the 28 day
compressive cube characteristic strength.
9.4.5 Joints
The faces of joints shall be cleaned before bolting segments together. Bolts shall be
tightened at the time of erection of each ring. For a shield drive the circle bolts shall be
retightened prior to release of the shoving force.
9.4.6 Rolled Rings
Rings may be rolled to facilitate the construction of openings, and may also be rolled to
facilitate maintenance of the plane of the rings. Tapered rings shall be rolled as
appropriate to achieve the specified alignments and gradients of the tunnels.
9.4.7 Bolts
The length of each bolt shall allow for two washers and two grommets and for all adjustments
required in the alignment of the shafts and tunnels. When fitted in position the bolt
threads shall be exposed for at least 3mm clear of the nut. See also Clause 9.6.3.
CONTRACT 1 Dec. 09
9.4.8 Plane
(a) Errors in the plane of a ring should be kept to a minimum. When they occur, the
plane of the ring shall be adjusted by packing of maximum practicable continuous
lengths of resilient, durable consented-to material. Packing in a single joint shall
not exceed 6mm for concrete lining or 4mm for SGI lining.
(b) The packings shall be supplied in various thicknesses, as required, but not less
than 2mm, and when in place, shall be clear of the sealing strip.
(c) In tunnel drives which utilise all tapered rings, packing shall not exceed 3mm per
circle joint.
9.4.9 Sealing Strips
Sealing strips of the hydrophilic or gasket type or a combination of the two shall be
provided at all faces between segments to provide a seal against ingress of ground
water. The materials, strip dimensions and profile and the method of adhesion to the
segments shall be as consented-to by the Employer's Representative. Gaskets must be
capable of withstanding the anticipated water pressure when in use in the tunnel and the
Contractor shall supply test certificates or other information demonstrating this capability as
part of the design submission. Gaskets will not normally be used on handbuilt drives; the
maximum compressive force required to achieve the required watertightness under the
maximum expected range of joint displacement conditions shall not exceed 10kN/m.
Elastomeric gasket materials shall comply with the requirements of BS 2494 or equivalent
including resistance to chemical attack and microbiological degradation. The Contractor
shall submit full details of the gaskets proposed.
Immediately prior to the erection of a gasketed segment the gasket shall be checked for
cleanliness and position. The gasket shall be lubricated as recommended by the gasket
manufacturer.
9.4.10 Caulking Grooves
Caulking grooves shall be formed in segments in accordance with the design and this
Specification to ensure that caulking to circle joints and radial joints may be made
effectively continuous, the depth of caulked material in the joints being not less than
25mm.
Prior to caulking, all joints shall be inspected and thoroughly cleaned out as necessary.
Any packing, grout or other foreign material projecting into the caulking space shall be cut
out by an appropriate method.
Immediately prior to caulking, the joints shall be blown out with a compressed air jet as
necessary to eject any loose debris or water.
9.4.11 Grout Valves
Grouting shall be carried out to provide the earliest practicable support of the ground by
each new ring of lining. For lining built behind a tunnelling machine continuous grouting
may be carried out via pipes at the tailskin of the machine during each advance of the
machine.
For linings built behind tunnelling machines having a pressurized face system, grout
holes shall incorporate one-way valves to prevent ground and water loss during the
grouting operation.
9.4.12 As-built Tolerances
In general the as-built segmentally lined shaft or tunnel shall conform to the tolerances
noted below. The Contractor may propose alternative tolerances as part of his design
submission.
CONTRACT 1 Dec. 09
(a) The acceptable tolerance on the position of the internal profile of the tunnel lining
is related to its internal diameter. The position shall be such that the track
alignment, inclusive of its positional tolerance and clearance gauges, as shown
on the Tender drawings. If the actual internal diameter is equal to the nominal
internal diameter (5700mm) of the single track tunnel, the internal profile of the
lining shall not depart from its design position by more than 75mm.
(b) The internal profile of any ring of shield-driven tunnels shall not deviate from a
true circle by more than 25mm. That is, any diameter of the as-built ring shall not
differ from the design internal diameter by more than 50mm.
(c) The plane of the leading face of each ring, including a taper ring, shall not depart
at any point from the plane surface by more than 6mm.
(d) Steps between abutting segments shall not be greater than 5mm.
(e) The roll of adjacent circle joint bolt holes shall not be greater than 5mm; the
maximum total allowable bolt hole roll of any ring is 40mm from the design
position.
9.4.13 Non-Compliance with Tolerances
Where any part of the lining does not comply with the specified tolerances the Contractor
shall submit to Employer's Representative for consent, proposals for remedial or other
measures to correct the defect or negate its effects as appropriate.
9.4.14 Damaged Segments
Any segments which are damaged or defective shall be indelibly marked and removed
from the Site and replaced by the Contractor. Such damaged or defective segments shall
be destroyed. No damaged or defective segments shall be used in the Works.
Rings which have been built and shoved and are subsequently damaged may have to be
removed and rebuilt.
9.5 Spheroidal Graphite Iron Lining (SGI Lining) Cast iron -
9.5.1 Quality of Materials and Castings
(a) Materials shall conform to BS 2789: Grade 600/3 or as otherwise approved.

Verification of the minimum 0.2% proof stress is required. All test results shall be
confirmed by test certificates.
(b) Castings shall be sound, clean and free from defects which may affect their
serviceability. They shall be properly fettled and free from sand, flashes etc.
before receiving the protective coating specified.
9.5.2 Testing
(a) For each type and size of tunnel lining ring and on preproduction castings or on
castings included in the first five production rings the manufacturer shall carry out
the following tests in order to confirm their freedom from internal defects:
On pre-production castings or on castings included in the first five production

rings, for each type and size of tunnel lining ring:
(i) Spectrographic examination of each pour to determine the percentage

composition of materials.
CONTRACT 1 Dec. 09
(ii) Ultrasonic testing of all critical points, using appropriate equipment and
methods. Subsequent to such testing and any testing required in (iii)
below, the Contractor shall propose standards of allowable defects to the
Employer's Representative for his consent.
An example of allowable defects would be small internal cavities at
junctions between elements of the castings, provided that after any
necessary machining they will remain well below the surface.
(iii) Sectioning or X-ray examination, at the manufacturer's choice, of any
defective areas as indicated by i) above where there is doubt as to the
significance of such defects.
(iv) Microstructure examination of material from at least 5% of castings
selected at random.
(v) Hardness tests on at least 5% of castings, including those in (iii) above.
Subsequent to such testing the Contractor shall propose for the
Employer's Representative's consent standards for allowable hardness
within the range 192 to 269 HB.
The manufacturer shall carry out such additional tensile tests as may be
required for the proper correlation of hardness, strength and
microstructure.
(vi) Where sonic or ultrasonic velocity testing is to be used during production
testing (see (f) below), such preliminary tests shall be carried out, as may
be necessary to establish the mean characteristics and allowable
deviations for the specified material.
(b) The following tests shall be carried out during routine production:
(i) Ultrasonic testing shall be carried out on 5% of all production castings. In
the event of significant defects occurring ultrasonic testing shall be
carried out on a greater number of castings, and in the case of doubt as
to the significance of such defects X-ray examination shall be carried out.
(ii) Hardness tests on 5% of all production castings.
(c) Any castings not satisfying the Contractor's quality standards as consented-to by
the Employer's Representative shall be rejected. Making good of general surface
defects will only be carried out where such defects are minor. Repair by welding
will not normally be carried out. All making good and repair procedures shall be
submitted in advance to the Employer's Representative for approval.
(d) Except as otherwise agreed by the Employer's Representative, all tests shall be
witnessed by his Representative.
(e) (i) The weight of castings shall be calculated from the consented-to
drawings, based on one cubic metre of metal having a weight of 7.20
tonnes.
(ii) The weight of castings shall not be below the weight so computed.
Segments less than the computed weight will be rejected.
(iii) Copies of all delivery notes of cast iron linings showing the weight of
each type of segment included thereon shall be made available for
inspection by the Employer's Representative. Delivery notes showing
inclusive weigh-bridge weights of various types of segment will not be
accepted unless they give the make-up of this weight.
(f) The number of tensile tests to be carried out shall be in accordance with Clause
5 of BS 2789. The manufacturer shall provide sufficient samples for testing
including the extra number required by BS 2789 in the event of a test failure.
In addition, in the case of any individually treated ladle not having a test sample
made from it and a tensile test carried out, one casting made from such ladle
CONTRACT 1 Dec. 09
shall have at least one sonic or ultrasonic velocity test and at least one hardness
test carried out on it or shall be subjected to a microstructure analysis. If the
treatment to produce nodular graphite is carried out in the mould then additional
testing shall be carried out to the approval of the Employer's Representative to
ensure that the correct metal quality is achieved.
(g) Washer pads where required on bolted linings shall be formed with faces
perpendicular to the bolt holes.
(h) Grout holes may be either cored or drilled, perpendicular to the skin of the
casting.
(j) Fillets shall be to the radius required in the consented-to design. Sharp corners
resulting from the repair of damaged fillets in the moulds will not be acceptable.
9.5.3 Machining, Drilling and Bolting
(a) Machining shall be to grade N10 as defined in Table 2 of BS 1134: Part 1.

Machining and/or drilling may only be carried out before application of the coating
system. All castings shall have the radial flanges machined to correct form and
dimensions defined by the design and this Specification.
Where shown on the consented-to drawings circle flanges shall also be
machined in accordance with this Specification.
(b) The machined faces of segments shall be plane and the radial flanges shall be
square to the circle flanges or at such other angle as the design requires, within
the tolerances specified. If bolt holes in circle flanges are cored then they shall be
elongated circumferentially by 5mm. In radial flanges bolt holes shall be either
gang or jig drilled or cored.
All bolt holes shall be neatly and evenly made. They shall be perpendicular to the
exterior face of the flange, except where otherwise shown on the consented-to
drawings.
(c) Grommet recesses may be cored or machined.
(d) Where countersinks are required, they shall be machined concentric with the bolt
holes.
(e) Where castings are bolted together in the works to provide segments for erection
the manufacturer shall ensure that such connections are suitable for the delivery
and erection of the segments without distortion or damage to the assembled unit.
9.5.4 Tolerances
The dimensions of SGI segments shall be within the following tolerances:
(a) Dimensions over a machined face 0.5mm

(b) Thickness deviation over any particular +3mm/-0mm
point from theoretical
(c) Internal diameter of a completed ring +6mm/-0mm
up to and including 5750mm dia
(d) Internal diameter of a completed ring +0.15% -0%
over 5750mm dia of theoretical dia
(e) Bolt holes:
(i) Drilled diameter +0.5mm/-0mm
(ii) Drilled Centres 1mm
(iii) Cored Centres 2mm
(iv) Pitch Circle diameter 3mm
(f) Caulking groove
CONTRACT 1 Dec. 09
(i) Half width dimension 1.5mm

(ii) Depth 1.5mm
(g) Sealing groove
(i) Depth 0.5mm
(ii) Width 0.5mm
(iii) Deviation from pitch circle
diameter shall not exceed 1.5mm
(iv) Cross match error at corner
not greater than 1 mm
(h) Steel templates or gauges shall be provided for the inspection of the tolerances
and control of the production of segments.
9.5.5 Painting and Protective Coatings
(a) Blast Cleaning

(i) All surfaces which are to receive subsequent treatment shall be blast
cleaned to fine grade according to BS 7079.
(ii) On completion of blast-cleaning, the segment shall be removed to a
separate area for application of any subsequent treatment.
(iii) The maximum amplitude of the profile produced (top of peak to bottom of
trough) shall not exceed 100 microns and shall give an average
amplitude of 45 microns.
(iv) Where extensive grinding has been necessary, the dressed areas shall
be reblasted to remove all rust and provide an adequate key for the
coating.
(v) After blasting, all spent shot or grit shall be removed. If any shot or grit is
found under or embedded in the coat film the affected area shall be
reblasted and the complete coating system reapplied.
(b) Machined Surfaces
Machined faces shall be protected immediately after machining by an application
of an approved rust preventive solution (Shell Ensis, Grade 260, or similar), no
further treatment being required.
(c) Painting
The coating to tunnel segments shall be such as to protect the segments both
during construction and during the design life. A minimum dry film thickness of
180 microns of Amerlock 400 or similar as consented - to by the Employer's
Representative shall be applied to all un-machined surfaces.
(d) Stacking, Handling, Transportation and Erection
(i) Segments shall not be moved from the spray shop until the coating has
hardened sufficiently to withstand handling. The minimum drying time
shall be agreed with the coating supplier prior to commencement of the
work.
(ii) Segments shall be stacked clear of the ground and palletized prior to
being transported from the foundry. Segments shall be adequately
protected from each other to avoid damage during handling and
transporting.
(iii) Loading onto tunnel bogies and subsequent erection methods shall be
designed to avoid damage to the coating.
CONTRACT 1 Dec. 09
(iv) After construction the inside of the tunnel shall be cleaned with a high pressure
spray, using potable water, to permit examination of the coating.
(v) Segments shall be inspected under the Contractor's Quality procedures
on completion of each tunnel drive. Where the coating has been
damaged, it shall be prepared and repaired to the standard required for
the original coating. The proposed coating for repair must be suitable
and safe to use in the tunnel environment and shall be tested and
approved accordingly.
9.5.6 Caulking
(a) Caulking material for SGI segments shall be lead unless otherwise agreed by the
Employer's Representative. The lead shall be more than 99% pure.
(b) The lead strips shall be supplied in a range of thicknesses to suit the as-built
segment joints and with sufficient depth to fill the caulking groove once the lead is
hammered into position.
(c) The lead strip shall be supplied in the form of rolls, or strips, of length more than
one third of the circumference of the ring, to minimise the jointing in the
completed caulking of the circle joint. The lead shall be chamfered to ensure
watertightness of the joint.
(d) The longitudinal joint caulking shall be in one continuous length between circle
joints.
(e) The lead shall be hammered into a cleaned caulking groove using pneumatic or
electric percussive hammers with a range of blades to match the as-built groove
widths.
(f) Retightening of the lead shall be carried out in locations where leakage occurs.
Prior to commencement of retightening of the lead caulking, the Contractor shall
ensure that the surface of the lead is thoroughly clean. Power tools shall not be
used for retightening of the lead.
(g) Where water leakage persists after retightening has taken place, the joint shall be
cleaned out and recaulked, using new lead of suitable dimensions, in order to
achieve the specified watertightness, giving special attention to junctions
between the recaulking and the original lead.
9.5.7 Grout Holes
Unless otherwise shown on the consented-to drawings the grout holes in SGI linings shall
be threaded throughout their length in the segments, and for a minimum depth of 25mm
in the inner face of solid key segments, with 32mm (1.25") parallel pipe threads
conforming to BS 21, except that the tolerances shall be such that when grout plugs are
engaged by hand the large end of the threaded part protrudes from the holes by at least
three threads. An internal boss shall be provided at each grout hole to provide not less
than the minimum thread length.
As soon as threads are fully prepared they shall be greased and a plug shall be screwed
in from the intrados sufficiently tightly to prevent its becoming loosened or lost in transit.
9.5.8 Grout Plugs
(a) Grout plugs for threaded grout holes shall be malleable cast iron taper screw
plugs of standard 32mm (1.25") thread, conforming to BS 21.
(b) The heads and the screwed parts shall be solid, conforming to BS 143. The
malleable iron from which the plugs are made shall comply with BS 6681
Malleable Cast Iron Castings, Grade B30-06.
(c) With each consignment of plugs, the supplier shall supply at his own expense a
manufacturer's certificate that they comply with the requirements of these standards.
CONTRACT 1 Dec. 09
9.6 Precast Concrete Linings
9.6.1 General
The Contractor shall supply, for the Employer's Representative's consent, details of the
segments including mix design, grading and source of aggregate, method of compaction,
curing period and methods, moulds and fixing of reinforcement and grout pipe assemblies
together with details of any tests or other data which may be relevant.
The concrete shall comply with Section 5 of this Specification and with requirements of
the Outline Design Specification.
9.6.2 Materials
(a) The requirements of Section 5 shall apply to this section except that where the
manufacturer can satisfy the Contractor and Employer's Representative that the
required works cube strength has been consistently attained and that the
provisions of this Specification are complied with, the trial mixes and associated
tests may be waived at the discretion of the Employer's Representative.
(b) The grade of concrete shall be at least between 40 MPa and 44 MPa on the 28th
day compressive cube characteristic strength
(c) The requirements of Section 5 shall apply to any reinforcement included in
segments for the permanent works to resist handling stresses.
(d) The Contractor shall obtain the Employers Representative's consent to all
admixtures, release agents or curing components used before production begins.
(e) The Contractor shall submit his details of the proposed mix including, if
appropriate, proposed cement replacements. Test mixes will be required prior to
production work commencing. Samples shall be tested at 28 and 56 days for
porosity, density and impermeability to water. Permeability tests shall be carried
out in accordance with any of the methods detailed in Concrete Society Technical
Report 31 or equivalent standard. The coefficient of permeability obtained from
such tests shall be a maximum 1 x 10-12m/s. The concrete shall also have a gas
permeability value not greater than 5 x 10-8m/s.
9.6.3 Connections
(a) The connections between segments, both radial and circumferential, may be
either bolted or to a consented-to manufacturers' patented system.
(b) Details of the manufacturers' alternative fixing method shall be submitted to the
Employer's Representative for his consent prior to the commencement of
manufacture.
(c) The fixings shall not impair the durability of the lining.
(d) If the segments are connected with bolts, the bolts are to be removed, after
grouting and not closer than 100 m behind theTBM-tail.The Contractor shall
ensure, that there is sufficient tension on the sealing. In areas, where it is
possible that the segments move in longitudinal direction (e.g. at tunnel end), it is
not permitted to remove the bolts. The length of these areas has to be calculated
and verified. The material of all bolts, which are not removed, must be resistant to
corrosion. Reuse of removed bolts is permitted provided they are checked for
damage or strain.
9.6.4 Moulds
(a) The Contractor shall submit drawings and details of the moulds he proposes to
use, and details of working methods he intends to adopt for their manufacture,
use etc. for consent.
CONTRACT 1 Dec. 09
(b) The Employer's Representative may give consent to moulds subject to

satisfactory prototypes being produced and sample segments being cast. Once a
standard has been agreed, a sample of this shall be kept unused, suitably stored
and protected for reference purposes.
(c) Moulds shall not be of a material which may warp through exposure. The
Contractor shall ensure that the moulds are protected such that there is no
detrimental effect on the casting due to changes in temperature.
9.6.5 Filling of Moulds
Before placing concrete, the moulds shall be inspected for cleanliness. Any build up of mould
release oil shall be removed prior to placing the reinforcement. The concrete shall be placed
directly into the moulds and as quickly as possible after mixing. It shall be compacted in such a
manner as to produce concrete which shall be dense, homogeneous and free from voids. All
surfaces shall be sound and free from honeycombing, blowholes and excrescence. No
repair of defective segments will be permitted.
9.6.6 Grout Holes
All grout holes are to be minimum 50mm diameter and fitted with a coarse thread to take
a grout plug which shall be manufactured from a suitably durable material and be capable
of tightening with a spanner. If a manufacturer's proprietary system is proposed, use shall
be subject to the Employer's Representative's consent. See also Section 9.4.11.
9.6.7 Tolerances
The dimensions of precast concrete segments shall be within the following tolerances:
(a) Circumferential length +3mm/-0mm

(b) Thickness +5mm/-1mm
(c) Width +1mm/-1mm
(d) Internal diameter of completed ring +8mm/-0mm
(e) Bolt holes: size +1mm/-0mm
(f) Bolt holes: position +1mm/-1mm
Steel templates fit for purpose shall be provided for the control of the production of
segments to the required tolerances.
9.6.8 Joints
The meeting faces of the bolted segments shall be cast such that when a complete ring is
bolted together, the ring is circular and with all faces of the longitudinal radial joints
meeting. The circle joint faces shall provide a plane surface for adjoining rings.
For a bolted ring design, a strip of stress distribution membrane is to be incorporated in

each circle joint and each radial joint.
9.6.9 Casting, and Curing
The Contractor shall comply with the requirements of Section 5 of this Specification for
casting and curing of precast concrete segments.
9.6.10 Concrete Cover
Cover spacers shall be plastic or a consented-to equivalent. Cover shall be determined to

provide the required durability in the prevailing ground conditions, but shall not be less
than required by the Design Specification.
CONTRACT 1 Dec. 09
9.6.11 De-Moulding
The segments shall not be de-moulded until the concrete has achieved 30% of the 28
days characteristic strength.
9.6.12 Handling and Stacking
At the time of handling and stacking, segments shall have attained the strength required
to avoid being damaged or overstressed. Spacers shall be used between stacked
segments but the spacers shall not be cast into the segments and shall be easily
detachable. Segments shall be carefully stacked on edge in a stable manner.
9.6.13 Caulking
Caulking material for precast concrete segments shall be Expandite PC4 AF or

equivalent consented-to material. The material shall be applied to clean joints in
accordance with the manufacturer's instructions.
9.7 Alternative Tunnel Lining
Should the Contractor propose to use an alternative form of tunnel lining he shall submit
for consent comprehensive details of his proposals. Such proposals shall include details
of materials, method statement, specification and design sufficient to demonstrate
compliance with the design requirements.
If such proposals, or any modifications to them which may be submitted, cannot be

consented to, the Contractor shall adopt the lining types and methods specified herein as
appropriate to the Works.
9.8 Grouting
9.8.1 Definitions
(a) The term `cavity grouting` shall mean the grouting required to fill the cavities or
voids between the excavated profile and the permanent linings to the
underground works, including voids due to ground relaxation, and/or the void
between the permanent and temporary linings. Cavity grouting shall generally be
carried out in two stages, primary and secondary grouting.
(b) Primary grouting' refers to the initial cavity grouting which takes place
immediately after the ring has been built, or in the case of a shield drive, during or
on completion of the shield shove.
Primary grouting will be an initial void filler and be to a pressure of not more than
1 bar above the surrounding hydrostatic pressure.
(c) Secondary grouting' refers to the subsequent regrouting of rings. This shall be
completed as soon as is practicable, but within 14 days of the ring build or 50
metres from the face, whichever is the most critical. Secondary grouting shall be
at a pressure not greater than 6 bars, consistent with completely filling all voids.
(d) Compensation Grout shall be carried out within 72 hours after tunnel boring
where soft clay is encountered or the bored tunnels are locate in close proximity
to soft clay.
9.8.2 Method
Prior to commencement, the Contractor shall submit proposals for cavity grouting and
compensation grouting and obtain the consent of the Employer's Representative. The
proposals shall include details and location of the mixing plant and grout pump(s), mix
design and constituents, pumping rates and pressures, injection points, the methods of
monitoring, recording and controlling the sequence and timing of grouting, the method of
preventing grout leakage, and details of the relevant experience of the personnel and
supervisors.
CONTRACT 1 Dec. 09
9.8.3 Mix
(a) The grout shall be a mixture of Ordinary Portland Cement and water with a
water/cement ratio in the range of 0.35 to 0.5 by weight as appropriate to the
circumstances. PFA, GGBS or additives such as plasticisers or non-shrink
agents excepting those containing calcium chloride may also be proposed.
(b) The grout shall be colloidal and the grout mixer shall be positioned near to the
point of injection. The grout shall be sufficiently fluid to ensure that it flows freely
into all parts of the cavities to be filled.
(c) Proprietary grouts may be used, subject to the Employer's Representative's
consent.
9.8.4 Injection
(a) The grout shall be injected, through grout holes provided in the linings or via
pipework attached to the shield tail skin, by positive displacement pumping. The
Contractor shall ensure that grouting pressures used are consistent with his
proposals and shall adopt appropriate methods and procedures for controlling
and monitoring the process.
(b) Cavity grouting to segmentally lined tunnels shall proceed from an injection point
in the tunnel invert and shall continue in such a manner that air and excess water
are expelled from the cavity progressively ahead of grouting. Stopcocks may be
used in order to allow the grout hose to be disconnected, so that the grout can be
maintained under pressure until it has set. After the grout has set the stopcocks
if used shall be replaced by the permanent plugs as a separate operation.
c) The Contractor shall ensure that the sealing material adopted at the leading edge
of the ring shall prevent grout loss. Rings shall be restrained by packing or other
means to prevent distortion or flotation, whilst allowing the free flow of grout in the
void. The Contractor shall ensure that the sealing material remains clear of the
leading edge and grout holes. The sealing material shall be removed upon
completion of the cavity grouting.
9.8.5 Grout Plugs
Upon completion of grouting, all grout plugs shall be greased and plugs shall be fully
tightened into the segment.
9.8.6 Records
The Contractor shall record, at each stage of the grouting process, the quantity and type
of grout and the pressure applied at each injection point. Grouting records shall be held
in the Contractor's offices and be available for inspection by the Employer's
Representative.
9.8.7 Monitoring Pressures
The Contractor shall monitor secondary grouting pressures and quantities to ensure that
grouting does not damage the Works or third party utilities, installations or structures.
9.8.8 Caulking
Where caulking is specified it shall be carried out after completion of primary and
secondary grouting.
9.8.9 Shafts
Primary grouting to shafts constructed by underpinning with segmental linings shall be

carried out after the erection of each ring. The gap around the perimeter of the bottom
ring to be grouted shall be sealed to prevent loss of grout under pressure and the seal
maintained until the grout has set.
CONTRACT 1 Dec. 09
9.8.10 In-situ Linings and Junctions
(a) All voids remaining unfilled outside the in-situ concrete permanent linings in
tunnels and shafts, including junctions, headwalls and the like, shall be grouted
as specified. For this purpose the grout shall be injected through pipes set in the
concrete, through drilled holes, or, where appropriate, through grout holes in
segmental linings or temporary supports.
Drilled holes shall not be used where there is a possibility that damage to the
Permanent Works could result, for example in puncturing of waterproofing
membranes.
(b) Where grout is to be placed in voids occurring within the design thickness of
linings the grout shall have a characteristic strength equal to the required
characteristic strength of the linings.
(c) Injection points used for cavity grouting shall be provided at least one per 2.0
linear metres of tunnel and more frequently in any areas of excessive overbreak.
The injection points for cavity grouting in arched roofs shall be located within
500mm of the crown. The injection points and sequences for grouting of shafts shall
be determined to ensure complete filling of the cavities.
(d) Grout pipes set in concrete shall be fitted with means of preventing blockage and,
before injecting grout, they shall be drilled or pricked through to provide a clear
passage for grout. Grout pipes and grout holes for grouting shall be at least
40mm diameter.
e) The grouting of the upper surface of concrete works in junctions and the like shall
be carried out through a series of grout pipes and vent pipes built into the
concrete for the purpose and extending to the highest part of the excavation. The
number and locations of pipes shall be determined to suit temporary ground
supports left in place, sufficient to ensure that cavities are completely filled.
(f) The grouting of the upper surface of concrete works shall be continued until the grout
emerging from the vent holes or adjacent grout holes is of the same consistency as
the grout being injected. No vented grout shall be re-injected.
(g) Where in situ concrete tunnel linings are backed by a waterproofing membrane or a
protective geotextile the grouting pressure shall not exceed 2 bars.
(h) Grout and vent pipes shall not be permitted to remain within 50mm of a finished
concrete internal surface and, when no longer required, all holes in concrete
linings shall be cleaned and filled with a consented-to polymer modified non-
shrink mortar.
9.8.11 Performance
The minimum strength requirement for the grout as measured from testing 100mm cubes
at 24 hours shall be 1.5N/mm2. The Contractor shall carry out his grouting operations
consistent with his method statement and with due cognizance of the ground conditions
at the time.
Setting times must be verified at Site with the aim of minimising ground movement and
floating of the tunnel lining.
9.8.12 Verification
(a) The Employer's Representative may require proof drilling to be carried out in the
crowns of tunnels and/or elsewhere at suitable locations and frequencies. All
voids encountered shall be fully grouted, and all drill holes filled using consented-
to non-shrink material.
(b) In the event that the cavities are not filled or the specification for watertightness is
not achieved after secondary grouting, further grouting through additional
injection points shall be carried out. Regrouting and the further grouting shall be
continued until a consented-to grouting pressure of up to 6 bars can be sustained
for 1 minute. This pressure shall be dependent upon the overburden and the
presence of adjacent structures.
CONTRACT 1 Dec. 09
9.9 Watertightness of Tunnel
(a) The watertightness of the tunnels as completed has to be as described in the

Outline Design Specification.
(b) The defence against leakage into the Works shall be provided by the cavity
grouting, the sealing strip incorporated into the tunnel rings and as a final
measure, grommet and caulking.
9.10 Pilot Tunnels
If required an approved Hand driven tunnels of 4000mm internal diameter and larger shall
be constructed, unless otherwise consented to, by first driving a temporary pilot tunnel
lined with bolted rings.
9.11 Daily Records
Daily records shall be kept at all tunnel faces of line, level, square, roll and plumb and the
diameter measured horizontally, vertically and diagonally of each ring erected.
Equivalent records shall be kept for shafts. The results obtained shall be tabulated
and/or plotted each day and copies of these held in the Contractor's site office where they
shall be available for inspection by the Employer's Representative.
For TBM drives daily records shall include details of the shield location and alignment, shove-
jack pressures, face pressures, spoil volume and grouting volumes and pressures.
9.12 Geological Record
During excavation of the Works the Contractor shall compile a detailed and continuous
geological record with photographs and cross-sections where appropriate. On
completion of sections of tunnel the Contractor shall correlate all data into a Geological
Report, in a form acceptable to the Employer's Representative. The Report shall include
details of temporary supports built into the Works, the location and types of ground
treatment and be issued to the Employer's Representative in triplicate. The timing of the
submission of the Geological Report shall be in accordance with that for other submission
of as-built information, Clause ERG3 Employer's Requirements.
9.13 Backfilling of Shafts and Adits
Temporary shafts and adits shall be completely backfilled on completion of the Works.
Backfill material shall be Grade C10 concrete or equivalent which may be placed either
wet or dry. Adits shall be backfilled in sections working from the permanent Works.
Temporary bulkheads shall be formed at agreed intervals and the upper part of the adit
completely filled by grouting through pipes which have been installed into the adit roof.
The bulkhead shall be moved back in stages until the whole of the adit is backfilled.
Shafts shall be backfilled in layers not thicker than 250mm, each layer being thoroughly
compacted with an appropriate power rammer. The backfill material shall be
homogenous, no large pieces of concrete or "plums" shall be used. As far as practicable
all extraneous materials such as steelwork and temporary timbers shall be removed as the
backfilling progresses. Shaft linings shall be dismantled to two metres below finished
ground level and the site reinstated with suitable granular material compacted as
specified in Section 2 Earthworks. Details of temporary works left in place shall be
included in the as-built information.
9.14 Working Under Compressed Air (if necessary)

9.14.1 Medical Aspects of Work in Compressed Air
All work in compressed air shall be executed in accordance with the following documents
published in the UK:
(i) "Work in Compressed Air Special Regulations 1958" by the Ministry of Labour
and National Service, or the latest issue of the regulations and comply with such
other recommendations contained in:
CONTRACT 1 Dec. 09
(ii) "Work carried out under Compressed Air" published by the Institution of Civil
Engineers and the "Medical Code of Practice for work in Compressed Air" CIRIA
Report 44 and any other statutory instruments and HMSO forms.
A copy of the above publications shall be passed to the Employer's

Representative.
9.14.2 Use of Compressed Air
(a) Where, from information obtained from sampling ahead of the face or from other
sources, including reports and inspections by competent persons, the Contractor is
satisfied that, on the grounds of safety, potential hazards and/or risk of
unacceptable settlement that tunnel excavation should not proceed further,
except under compressed air working, he shall inform and provide details to the
Employer's Representative both of his reasons for proposing to adopt
compressed air working and of the proposed method of working including all
plant, procedures, safety provisions and measures to avoid noise nuisance from
compressor plant and air locks etc. at the surface.
(b) The Contractor shall pay special regard to the necessity for arranging the
compressors and the exhausts from the locks so that there shall be no excessive
noise or inconvenience which would be likely to disturb persons in the vicinity of
the Works.
(c) Consent will be subject to the requirement that the Contractor shall from time to
time consider whether, on the basis of information obtained as aforesaid, such
working may be discontinued and when satisfied, shall inform and provide necessary
information to the Employer's Representative accordingly. The Contractor shall
submit his proposals, for consent, for measures to be taken on (slow) reduction of
the tunnel pressure to atmospheric.
(d) Provisions shall be made through the air locks or bulkheads for such pipes and
conduits as may be required by the Fire Brigade in addition to those required by
the Contractor for his services.
(e) The Contractor shall copy, each week, to the Employer's Representative a list of
all employees, including the Employer's Representative and Contractor's staff,
examined by the appointed doctor and the maximum pressure in which each can
be employed. No employee whose name is not on this list shall on any account
be permitted to enter the air lock.
9.14.3 Compressed Air Retaining Installations
The Contractor shall design installations fabricated in steel, such as bulkheads and air
locks, and any brickwork or concrete bulkheads, to appropriate safety margins taking into
account maximum output pressures of proposed compressed air plant.
The Contractor shall provide oil-free air compressors with minimum capacity of 4
cu.m./minute per area of exposed tunnel face in sq.m., and minimum output pressure
shall be at least 0.5 bar above theoretical hydraulic pressure at tunnel invert. Emergency
generators shall be provided to run 50% of installed compressors in case of power supply
failure. Such generators shall be well maintained and equipped with automatic-start
function and switch-over system. Satndby compressors shall be provided in case of long
period working time.
9.14.4 Plant
(a) The Contractor shall submit details of his low pressure compressed air plant and
equipment indicating his provision for standby generators, air cleaning and
cooling plant.
(b) The plant shall be capable of supplying compressed air at the necessary volume
together with an allowance for standby at a pressure to balance the maximum
CONTRACT 1 Dec. 09
hydrostatic head plus any artesian pressure.

(c) Standby generators shall be test run by the Contractor at weekly intervals.
Appropriate records of tests of all plant shall be maintained in accordance with
the Contractor's quality procedures.
9.14.5 Locks
Where air pressures are required to exceed 1 bar, manlocks must have at least three
compartments. The Contractor shall allow for separate muck and material delivery locks.
9.14.6 Pressure Control
The Contractor shall maintain such air pressure as may be necessary for safe working
and shall provide facilities for varying the pressure accordingly.
9.14.7 Pressure Gauges
In addition to the gauges required by the Medical Code of Practice for Work in
Compressed Air (CIRIA report 44) further pressure gauges shall be installed in every working
chamber showing the pressure in the chamber and in the adjacent manlock.
9.14.8 Telephones
Each manlock or decompression chamber shall be connected by telephone to the

manlock attendant's post, which shall also be connected by telephone to the compressor
house attendant's post and subsequently to the emergency services.
9.14.9 Layout
A notice shall be provided at the airlock stating the air pressure within the plenum
chamber and showing the layout of the Works beyond the bulkhead and the distance to
the working face; these facts are to be updated daily. The emergency procedure in the
event of a fire shall be clearly stated on this notice. Such procedure shall be agreed with
the local emergency fire department.
9.14.10 Identity Cards
Each person employed in compressed air shall be provided with a laminated identification
card displaying a passport type photograph stating their name, employer, occupation and
reference number. This card shall be handed to the lock attendant before entering the
manlock. No person shall be allowed to enter the lock without handing in his identification
card. The manlock attendant shall display all cards on a suitable notice board for inspection
at any time. The procedures for air-lock access and decompression/egress times shall be
rigidly enforced.
9.14.11 Records
Copies of records of the working pressure, temperature, humidity and weather conditions,
number of decompressions and recompressions etc., together with a brief report on all
personnel who undergo recompression, shall be submitted weekly to the Employer's
Representative.
9.15 Minimum Requirements of Tunnel Boring Machine (TBM)
The Tenderer is required to enclose with his tender a comprehensive technical proposal
comprising an assessment of the geological conditions through which he will bore his
tunnels and provide a detailed description and reasons for his selected TBM and the
ancillary equipment. The manufacturer of the TBM and ancillary equipment shall be
named and advised to the Employer together with the corresponding drawings. In
addition, the Contractor shall provide a program for the TBM manufacture, delivery and
tunneling addressing all special measures.
CONTRACT 1 Dec. 09
The TBM shall at least satisfy the following minimum requirements (in addition to other
requirements defined by the Contractor).
If the proposed TBM does not satisfy these minimum requirements, the Contractor shall
explain in detail what alternative facilities/systems are available to ensure full control of
the tunnel drive, ring building and grouting.
Table 9.15.1 Minimum Requirements of TBM
1. Capacity to introduce compressed air support in the excavation chamber.
2. Man and material locks for access to the excavation chamber.
3. Capacity to inject grout in the roof and crown area as advanced consolidating material in
order to produce a solidified soil area in front of the shield (in exceptional cases).
4. The segment erector must be able to execute the following movements (actively separated
from others). The capacity for precise control of these movements must exist:
o displacement in tunnel direction to the tail sealing section
o rotation around the shield axis by 360 degrees
o radial launch and start up
o erector heads tilting in tunnel longitudinal and cross direction
o twisting of erector head
o segment handling
5. The TBM guidance control system has to ensure the continuous and immediate control of
the shield concerning the longitudinal, vertical and lateral position and the rotation of the
shield.
6. Computer data logging system shall record the TBM progress taking data from the guidance
control system. This data shall be recorded automatically and continuously on a data
medium.
7. Computer data logging system shall also record
o Grouting quantities and pressure per ring advance
o Hydraulic pressure of the shifting rams for every ram
8. Back-up trailer running on rollers, which are sufficiently dimensioned and fit to the segments
curvature.
CONTRACT 1 Dec. 09

Bangkok Mass Transit Blue Line Extension Project Specifications

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Bangkok Mass Transit Blue Line Extension Project Specifications

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KINGDOM OF THAILAND

BLUE LINE EXTENSION PROJECT

CONTRACT 1 : UNDERGROUND CIVIL WORKS

HUA LAMPHONG SANAM CHAI SECTION

OUTLINE CONSTRUCTION SPECIFICATIONS

Bangkok Mass Transit Consultants Consortium

TESCO Ltd. Thai Engineering Consultants Co., Ltd.

MAA Consultants Co., Ltd. IT International Co., Ltd

MASS RAPID TRANSIT AUTHORITY OF THAILAND

BLUE LINE EXTENSION PROJECT

CONTRACT 1 : UNDERGROUND CIVIL WORKS

HUA LAMPHONG - SANAM CHAI SECTION

OUTLINE CONSTRUCTION SPECIFICATIONS

SECTION 4 : PILING AND DIAPHRAGM WALLING

SECTION 6: PRESTRESSED MEMBERS

SECTION 7 : STRUCTURAL STEELWORK

7.20 Application of protective layers .................................................................................... OCS-124

SECTION 8 : ARCHITECTURAL AND BUILDING WORKS

SECTION 11 : SOIL IMPROVEMENT WORKS

SECTION 13 : NATM SPECIFICATIONS

LIST OF GENERAL ABBREVIATIONS

Note: International metric measurement units are not listed.

AASHTO American Association of State Highway and Transportation Officials

BMA Bangkok Metropolitan Administration

CAT CAT Telecom Public Company Limited

ECS Environmental Control System

FAP Fire Alarm Panel

JIS Japanese Industrial Standards

MEA Metropolitan Electricity Authority

O&M Operations and Maintenance

SCADA Supervisory Control and Data Acquisition

To be completed by the Contractor

To be completed by the Contractor

3 Section 4 Piling and Diaphragm Walling

To be completed by the Contractor

To be completed by the Contractor

5 Section 6 Precast Concrete

To be completed by the Contractor

6 Section 7 Structural Steelwork

To be completed by the Contractor

7 Section 8 Architectural and Building Works

To be completed by the Contractor

To be completed by the Contractor

9 Section 10 Cut and Cover Construction

To be completed by the Contractor

GUIDANCE NOTE TO THE SPECIFICATION

Department of Highways Specifications for Highway Construction.

TIS 395-2524 Standard for Precast Reinforced Concrete Piles

TIS 15 Portland Cement.

Section 6 Precast Concrete

Section 7 Structural Steelwork

TIS 49 Covered electrodes for arc welding of mild steel.

Section 8 Architectural and Building Works

NFPA 101 Life safety code

BS 4800 Schedule of paint colours for building purposes

9.1 Introduction OCS-224

9.2 General OCS-224

9.3 Excavation OCS-224

9.3.1 General OCS-224

9.4 Segmental Tunnel Linings OCS-228

9.4.1 Design OCS-228

9.5.1 Quality of Materials and Castings OCS-231

9.6 Precast Concrete Linings OCS-218