Saudi Tunnelling Company for

Contracting

METHOD STATEMENT OF
MICRO-TUNNELING
METHODOLOGY

Client:
National Water Company.

Main-Contractor:
Al-Manar Arabian Corp.

Project Name:
Construction of Sewage Pipe Line K-
DN 1200 mm

April 2020
 List of Contents

Section Title Page

1 SCOPE OF WORKS 03
2 OBJECTIVES 03
3 PERSONNEL ROLES AND RESPONSIBILITIES 04
4 TOOLS AND EQUIPMENT 05
5 CONSTRUCTION PROCEDURES 06
7 FACILITIES, BURRIED UTILITES 13
8 WORKING AREA, WORK PERMITS AND WORK HOURS 13
9 QUALITY PLAN 14
10 HEALTH AND SAFETY 14
11 ATTACHMENTS 23
11.1 RISK ASSESSMENT FOR MICROTUUNLING WORKS
11.2 RISK ASSESSMENT FOR LIFTING WOKS
11.3 JOB SAFTETY ANALYSIS FOR MICROTUUNLING WORKS

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
 1. SCOPE OF WORKS

The aim of this presentation is to describe the plan and the method statements of
execution to be followed for the installation of DN1200 mm Reinforced Concrete Jacking
Pipe by means of Micro-tunneling technique, and to provide technical description for this
technique that to be used in the Execution of Pipelines in shannan area.

2. OBJECTIVES

We propose to execute this project and install the DN1200 mm RCJ by using micro-tunneling
method of execution. The execution of the Thrust-boring part by using the Micro-tunneling
technique in Jeddah city.

MICROTUNNELING WORKS

Bill of Quantity for Tunneling by MICRO-TUNNELING Methodology:

DRIVE LENGTH
S/N LOCATION DESCRIPTION SOIL CONDITION
(L.M.)

Installation of DN1200 mm
1 Jeddah city. Rock Ground 180
RCJ Pipes with O.D1490 mm,

Total Quantity (L.M.) = 180

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
3. PERSONNEL ROLES AND RESPONSIBILITIES

3.1. Construction Manager

He is overall responsible for ensuring that the formwork installation is carried out in
accordance with this Method Statement.

3.2. Site Engineer

His responsibilities include:

• Supervision, coordination and control of the project.
• Distribution of work to the Site Foreman and Technicians.
• Reporting directly to the Project Manager on daily basis.

3.3. Technician / MT Operator

Execute the works on the site.

3.4. Foreman

His responsibilities include:

• Carrying-out the work and the proper distribution of all the available
resources in coordination with the Site Engineer on a daily basis.
• Daily reports of the works are achieved and coordinated with the Site
Engineer.
• Incorporate all the QA/QC and Safety requirements as requested by the
concerned Engineer.
• Attending to any type of unforeseen incident or requirement and reporting
the same to the Site Engineer immediately.

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
4. TOOLS AND EQUIPMENT

The following list shows list of equipment to be used for a typical micro-tunneling project.
Depending on project requirements, additional items may be added to this list.

S/No Description Qty

1 50-ton Crane RT (certified) 1

2 Excavator 1
3 Jacking Rig (Inc. spacers) 1
4 Inter-jacking Station, if required 1
5 Micro-tunneling Head 1
6 Control Container 1
7 Pipe Laser AC-1 1
8 Theodolite, Tripod and Staff 1
9 Leveling Device 1
10 Laser Range Meter 1
11 Bentonite Mixing Unit 1
12 Water Feed Pump (30kW) 1
13 Sludge Discharge Pump (45kW) 1
14 Boom Truck (Part Time) 1
15 Flat Bed Truck (Part Time) 6
16 Water Truck 1
17 Settlement Tank (24m3) 1
18 De-Sander / De-Silter unit 1
19 Tools and Workshop container 1
20 Office Container 1
21 Generator 55 kVA 1
22 Generator 410 kVA 1
23 Thrust Pit Construction and Bracing Materials As Req.
24 Concrete for Front Wall, Back Wall and Base Slab As Req.
25 Bentonite Clay As Req.
26 Process Water (raw) As Req.
27 Compressor 175 cfm 1
28 Diaphragm Pump 1
29 Dewatering Equipment As Req.
30 Safety Barriers & Signs As Req.

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
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5. CONSTRUCTION PROCEDURES

5.1 Execution of Works

Once two jacking shafts (start & target) are prepared for pipe-jacking works, the
micro-tunneling resources can be moved to site and the setup of the equipment will
proceed. The driving/launching shaft will be rectangular as it very depending on the
space available between the existing utilities.

Based from our machine specs of Jacking Rig, we would need to have for DN1200 mm
RCJ pipeline:

-Jacking Shaft to have clear inside dimensions 6.00 meters long, 6.00 meters wide
and Height from centerline to the top of concrete base slab is 1.18 m.
-Receiving Pit to have clear inside dimensions of 5.50-meters-long ,5.50-meters wide
and deep enough to recover the machine shield.

Final details and depth of shafts will be prepared once all site parameters (design,
shop drawing and pipe outer diameter size) are finalized and made clear.

The Reinforced Concrete jacking pipes form a string connected to the back of the
tunneling shield. As the shield advances through the ground, further pipes are
lowered in the drive pit and connected to the string at the drive/launch shaft by
coupling method. Reinforced Concrete jacking pipe is supplied on site in lengths
suitable to the size of drive shaft. Spoil from the excavated face may be removed by
a variety of means including auger flight, slurry pumping and on larger man-entry
constructions by skips, trucks and conveyers. And in our case, since we’re using a
slurry machine so the excavated material is conveyed to surface by slurry pumping.

Forward movement of the shield is achieved by operating hydraulic jacks positioned

in the drive/launch shaft. These jacks react against a thrust wall in the shaft. It is
often important to keep the string of pipes moving forward in order to avoid the
ground “gripping” a pipeline, which is stationery for too long. Upon completion of
the drive length, the shield is recovered at the reception shaft leaving a complete
installed product pipeline. The shield can be remotely steered, ensuring the correct
line and level of the pipeline. The initial alignment of the pipe jack is obtained by
positioning guide rails within the thrust pit on which the pipes are laid. Once jacking
starts, checking against fixed reference point controls the direction.

For long lengths of pipeline, intermediate-jacking stations may be necessary to allow

sequential thrusting of sections of the pipeline. Drives of several hundred meters
are attainable using this technique.

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
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 The concrete, steel or clay pipes used in this technique are specially designed to
ensure that all joints are flush within the pipe wall, and that they are strong enough
to withstand the jacking forces applied to them

5.2 Method Statement

We include for reference, a standard Method Statements for micro-tunneling that

would be a guideline for the thrust-boring procedure to be followed.

Micro-tunneling system consists of remotely controlled tunneling machine (or

shield). This system excavates a circular tunnel or borehole into which the product
pipeline is installed. Pipes to be installed are connected to the back of the micro-
tunneling shield. As the shield forms the bore, it is pushed forward by a set of
hydraulic jacks positioned in the drive shaft and guided by a railing frame.

Typical Remote-Control Slurry System Micro-tunneling / Pipe jacking (Schematic)

When a full length of Reinforced Concrete Jacking pipe is jacked into the ground,
new pipes are positioned into the frame, jointed to the pipe string and then pushed
forward. This process will continue until the micro-tunneling machine arrives into
the reception shaft located at the point where the bore will be finished. The only
excavations required are for the drive shafts and reception shafts. The following
figure shows a typical micro-tunneling setup for manhole-to-manhole installations.

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P.O. Box 16116, Jeddah – 21464, KSA
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 Excavation is carried out by a tunneling shield, which was equipped with different
types of cutting heads for different types of soils. The heads may be fitted with
blades for soft soil, picks for mixed ground and disc cutters for hard rock. The
ground conditions will have a large effect on the choice of Micro-tunneling system
for a particular situation, as they will determine the type of machine to be used, the
cutting head, the soil removal system and the jacking forces required.

Once excavated, the soil can be removed either by vacuum, mechanical auger or by
compaction around the bore. In the first of these systems, vacuum pressure is used
to suck the material from the tunneling face back to tanks on the surface.
Alternatively, a flight of augers running through the newly installed pipeline can be
used to convey the cuttings to the surface. In this system, the spoil is collected in a
skip and lifted out of the drive shaft. The auger system is preferred for short drives
since the removal rate is considerably faster than other systems.

In the slurry removal system, water and bentonite mixture is used to convert the
cuttings into slurry at the cutting face. This slurry is then discharged to the surface
through hydraulic lines located inside the carrier pipes. The soil is processed in a
settlement tank, where the solid particles are separated and removed; the recycled
effluent is pumped back to the cutting face. The slurry system is also used to
balance earth pressure and to prevent influx of groundwater at tunnel face.

Micro-tunneling machines are steerable in order to install pipeline in the correct

alignment and level. These machines are operated remotely from a control cabin on
the surface and whole process is monitored by computer systems. Laser beams and
cameras are used to monitor position of micro-tunneling shield very accurately.

5.3 Launch and Reception pits

The control container is set up on the natural ground at a suitable position near the
launch pit.

A launch shaft is excavated at the starting point of a pipeline crossing. This shaft
must be large enough to accommodate a full length of pipe segment.

A concrete blinding slab is cast on the bottom of launching shaft at the correct level
and gradient in order to set up equipment in a clean and safe environment. The rear
wall of this shaft is reinforced with a steel thrust plate of 2.5 x 2.5 m to bear the
large thrust forces generated while jacking the pipes (for the compact jack the wall
will be casted upon completion of the jack setup). Then, survey points are marked
on the concrete base slab for easy reference.

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
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 The reception shaft is an excavation prepared at the termination point of a crossing
and used primary to recover micro-tunneling head and carry out tie in works. This
pit at shallow elevations is typically constructed with the dimensions of 5.50-meters-
long and 5.50-meters wide and deep enough to recover the machine shield.

5.4 Cutting Head

The following figure shows a typical cut-away view of a Herrenknecht AG micro-

tunneling head. Different types of cutting wheel arrangements for various ground
types are also depicted in the upper right corner.

The cutting head of a micro-tunneling machine for mixed ground drilling is equipped
with hard metal cutting discs 180mm and 250/180 mm in diameter. Depending on
the size of tunneling machine, these cutting discs are located such that rotation of
cutting wheel will excavate entire face of a circular tunnel. Excavated material
passes through openings in the cutting wheel into the crushing chamber. The conical
crusher reduces the materials in size, mixed with water and bentonite to form a
slurry medium suitable for conveying to the surface with a sucking pump.

Hydraulic motors, located within the cutting head assembly, rotate the cutting
wheel. Thus, excavating and crushing power of a micro-tunneling system does not
depend on distance from the launch shaft as with an auger driven equipment.

The cutting head assembly consists of two sections that are articulated to allow
movement of up to approx. 3.5 degrees in any direction to enable precise steering
of the thrust. To customize the cutting head to the carrier pipe, a back-up pipe
piece about 3.0-m long has to be supplied by the Client (If required).

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
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 5.5 Control and Power Unit

The control and power module are housed within an ISO standard freight container
providing rapid relocation from site to site.

This unit contains pumps to generate enough hydraulic power to drive micro-
tunneling head, surface jacks and transfer pumps. Hydraulic fluids are pumped to
various components of the system via flexible hoses with quick couplings and
operated remotely within the container.

The heart of this container is a computer control system. This system monitors all
tunneling process in real-time by means of electro-mechanical sensors fitted to
various parts of the tunneling machine and generates digital indicators on the video
screen. Thus, tunneling operator will control all plant remotely and steer the line
pipe in the desired alignment and level.

This computer also triggers an alarm system if critical parameters fall outside of
expected ranges and alerts operators. Furthermore, these parameters are kept in
magnetic storage for quality indicators and as-built drawings.

5.6 Guidance System

The Slurry machines laser guidance system has been developed specifically for use
with Micro-tunneling systems. This system includes of a laser source, located in the
thrusting pit and pre-aligned accurately with the course of pipeline. This laser beam
passes through the product pipe and hits to a target system. This target (an
electronic laser camera) is fixed in the cutting head for the impinging laser beam to
define the exact position of the tunneling machine. A wheel encoder is located in
the launch shaft to provide continuous measurement of the length of thrust.
Through the main processor of computer system, the actual position of the cutting
head is calculated and displayed graphically on a color monitor built into the control
panel. The processor stores a complete record of the installation and a printout is
available at any time during the construction from the printer located in the
control/power pack module.

5.7 Tunneling Operation

The cutting head is pressed against the tunnel face by the power of hydraulic
cylinders located in the launching shaft. Powerful compacted jacking rig with two
hydraulic cylinders distribute the jacking force (max. 8548 KN) via a push ring on to
the jacking pipe to thrust the pipes forward. Pushing ring has an integral ratchet
device to allow movement of the pipes only in the pushing direction with the
hydraulic cylinders and prevents ejection of pipes by rational ground forces.

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P.O. Box 16116, Jeddah – 21464, KSA
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 When a complete length of pipe is driven into the ground, hydraulic cylinders are
pulled back to rear end of thrust pit. A new pipe is lowered into the pit and jointed
to the existing pipe. Then pushing ring is attached to the newly added pipe and a
new cycle of installation starts.

5.8 Material Conveyance

The reduced excavated material is mixed inside the cutting head with the feed water
to form slurry, which is discharged into a separation tank located outside the launch
shaft. This water is processed by a filtration unit to remove unwanted solid particles
bigger than a certain size. Then, processed bentonite slurry is feed into the tunneling
machine via flexible hoses passing through the pipe to be installed.

A by-pass valve system within the cutting head enables washing out of the lines and
partial re-circulation. These valves also isolate the cutting head, whilst the pipeline is
broken to insert a new carrier pipe. Thus, face support can be maintained, whilst the
slurry material discharge system is disconnected, when putting in a new jacking pipe.

5.9 Lubrication

Lubrication are being increasingly used to improve the performance of micro

tunneling. The lubrication may be affected by the addition of suitable agents at
various points throughout the tunneling process, such as around the outside of the
tunneling shield and/or the pipes in a tunnel, in our technique we are using special
physical and chemical characteristics of sodium montmorillonite clay called
BENTONITE.

This improvement may come as a support of excavated bore in pipe micro tunneling,
reduction of jacking forces in pipe jacking and micro tunneling, reduction in the
friction losses in the pipes, reduced friction and heat buildup in shield, better control
of groundwater inflow by reducing permeability (each 4 normal pipes the number
pipe number 5 will be bentonite pipe).

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
 Lubrication System

5.10 Manpower

The following table shows required manpower for a typical micro-tunneling project.
Depending on project requirements, additional manpower may be included in the
list.

No Description Qty

1 Construction Manager (Part Time) 1

2 Micro Tunneling Operator 1
3 Site Engineer 1
4 Forman 1
5 Mechanic 1
6 Electrician 1
7 Arc Welder 1
8 Thrust Bore Helper 4
9 Night Watchmen 2
10 Heavy Duty Driver (Part Time) 2
11 Crane Operator (Contractor) 1
12 Excavator Operator (Contractor) 1

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
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 6. Facilities and Buried Utilities

The following facilities and services are requested and must be provided by the Contractor:
1- Adequate access routes from hard road to and between storage and working
areas, prepared and maintained throughout the working period, to allow for
complete mobility and full support to our plant and attendant vehicles; radiant
not to exceed 1 at 12.
2- Disposal of surplus excavated drilling materials and effluent from the sites.
3- Site coordinator

Location and marking of all existing buried utilities are to be carried out by the Contractor
prior to STCC arrival on site. All construction drawings “approved for construction” are to
be supplied to STCC one week before mobilization to job site.

7. Work Area, Work Permits and Work Hours

1- The working area at the mine face shall be kept clear by means of a vacuum tube,
which shall transport the spoil and slurry to a container outside the pipe.
2- The full length of the pipeline shall be kept clear of unnecessary obstructions as to
allow easy passage of workers and equipment of the mine face.

All hoses pipes and tubes require for the work shall be run neatly along the bottom of the
pipe to avoid obstructing the free movement of the trolley.

1- Prior to the Thrust-boring works, all permits, ID’s and vehicle stickers required for the
site(s) have to be supplied by the Client to the STCC Site Supervisor. The client has to
take care of all warranties required by Municipalities.
2- The Thrust-boring works do require a 12-hour shift during day or night, 6 days per
week, except for national days; all permits are to take care of this.
3- In case the Thrust-boring works do require double shift (24 hours per day) for any
reason, the Client is responsible for the permits.
4- Hot, Cold and Confined Space Permits shall be obtained in accordance with G.I.2.100.
5- Work Permit Receives shall be fully trained in the type of work being performed and
be aware of potential hazards involved.

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
 8. QUALITY PLAN

All works will be executed according to the standards as set by the Clients and
involved authorities.

Reporting has the key role in order to maintain an acceptable quality plan. The
following reports are prepared whenever required.

1 - Daily Progress Report: These reports are detailing plant & equipment in use
and occurrences observed in a daily shift session. These reports are prepared
by field supervisor as per STCC procedures and signed by Client’s
representatives.
2 - Alignment Report: This report is filled in daily (or each shift) and information
is given to client immediately.
3 - Job Completion Certificate: This certificate will be produced after finalization
of each crossing. It indicates length, dates, sizes, etc. of the installation. This
certificate will provide an undisputable document for subsequent invoicing.

9. HEALTH AND SAFETY

• STCC will ensure safety of personnel as per Project standards

• All personnel involved will use necessary PPE as required such as safety helmet,
glasses, coverall, shoes, gloves, ear plugs etc.

• The workers will made aware of the safety requirements related to this activity
through daily toolbox and safety talk.

• All required work permits will be acquired and kept available at respective work Site
hanged clearly in plastic folders.

• Spark arrestor and warning lights will be installed on all mobile equipment.

• STCC will inspect all equipment prior to use.

• Every effort shall be made to assure that employees can accomplish their assigned
scope of work safely.

• The ability to determine the storage areas, access, potential and existing hazard on
the will identified the facilities for welfare, first aid and sanitation, the work permit
procedures and requirements and the basic precautions on dealing with fire hazard
and damage to property at the planning stage.

• Ensure the proper sequence of construction operations, outline potential hazards at

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
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 each stage and indicate the precautionary measures to be adopted on site by the
area foreman / site supervisor. Carry out checking over work methods and
precautions against supervision prior the commencement of work.

a. PERSONAL ROLES AND RESPONSABILITIES ON SITE

 Construction Manager

He is overall responsible for ensuring that the formwork installation is carried

out in accordance with this Method Statement.

 Site Engineer

1. The site engineer will ensure that the site preparation activities are
conducted according to the approval Method Statement.

2. It is the site supervisor s responsibility to organize the work in a safe

manner to ensure that safety and protective equipment are being properly
utilized. He must also ensure that the safety requirements is implemented
and the approved Method Statement procedure is followed and the ITP is
applied.

b. Risk Assessment & Job safety Analysis

All safety precaution as per STCC safety plan should be applied for all the activities
involve on the micro-tunneling works (see Job Safety Analysis below Attachment No
11.3 and risk Assessment sheet, Attachment No 11.1)

c. Evacuation and Emergency plan.

Workplace emergency is an unforeseen situation that threatens employees disrupts

operations or causes physical or environmental damage, the decision to evacuate or
shut down operations. Protecting the health and safety of everyone in the facility
should be the first priority.

In case of emergency evacuation sequence of an evacuation can be divided into the

following phases:

1. Detection: To observe in case of any emergency such as fire, Toxic gases release
etc.
2. Decision: decide to evacuate or shut down operations. Protecting the health and
safety of everyone in the facility should be the first priority.
3. Alarm: alarms are distinctive and recognized by all employees as a signal to
evacuate the work area or perform actions identified in your plan

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
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 4. Movement to an area of refuge or an assembly station: Emergency escape
procedures and route assignments, such as workplace maps, and safe or refuge
areas

d. Evacuate injured person from workplace.

During execution of the work any labor exposed to injury in work place area such as
falling down, Fire, Eye Damage, Cuts, and Burns. In case of Microtunneling work
here below some Precautions regarding the Microtunneling activates and safety
issue.

i. The lifting equipment (Crane) permanently parking near the shaft with
operator.
ii. Main basket placed near shaft
iii. One person to guide the crane operator during any lifting activity

In case of any Injury inside the shaft during execution of work the following the plan
to evacuate for injured labor.

iv. After notification of the injured person the safety officer will contact for
medical support.
v. Meanwhile the person who guide the crane operator will give the signal to
crane operator to hold the main basket. And send it to inside the shaft.
vi. Labor who are working inside shaft give first aid and once they received the
main basket, they put the injured person inside the main basket.

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
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 vii. The person outside the shaft who guide the crane will make sure the injured
person has been put inside basket safely and after that He will give signal to
crane operator to lift main basket to carry out the injured person.
viii. Once the main basket with injured person reached at the surface area, he will
be kept in a comfort place under observation until medical support reached
at site.

- As per our health and safety rule we ensure safety of employee in workplace.in
case of any serious injuries or unintentional accident inside the work place our
safety office will investigate about the accident and advice the employee inside
the work place to prevent or keep them away from the such similar accidents in
future

e. Lifting Plan
i. Introduction

 Purpose

This document provides the procedure to be used for lifting equipment’s operational
best practices. It’s defined and describes the equipment & safety procedure which
are to be employed by the lifting equipment’s user to carry out the lifting operations.

Competent & qualified personnel using the correct equipment in a safe manner is
the key of the safe lifting operation. This procedure will outline the issues relating to
the selection of the correct people for the task. It will describe the operational
practices to be used by these people as part of a safe and effective crane and rigging
program.

Generally, in Micro tunneling works when mobilize equipment to job site working
team placed the all Microtunneling equipment in a proper place as per the jobs site
requirement for this purpose we are using a suitable crane for lifting these
equipment, once we complete equipment setup on the surface we did the necessary
connection between the equipment and we will not lift it until complete the project
totally.

We fix the crane near the shaft area to execute the Microtunneling works
(Installation of pipe: When a full length of Reinforced Concrete Jacking pipe is jacked
into the ground, new pipes are positioned into the frame, jointed to the pipe string
and then pushed forward).

 Scope
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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
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 This procedure applies to all lifting operations. The lift planning process describes the
systematic assessment of important load factors and site factors. It is as applicable to
“simple” routine lifts as well as “heavy” non-routine lifts. Planning a non-routine lift
requires considerable effort. In a lift determined to be non-critical, many of the
elements can be determined "by inspection"; and the depth involved in a non-
routine lift will not be required. Nevertheless, the planning process must be followed.
This procedure prohibits a person from riding or travelling on the load, lifting hook,
sling, platform or other lifting medium.

ii. Role and Responsibility

WHO WHAT

To identify the need for a crane based on his work scope

Project/Zone Manager requirement.

To review and approve lifting plan and operation submitted

by contractor/crane supplier via the Executing Department
Site engineer as and when required. To constantly monitor the approved
plan and identify improvement for future

To establish crane capacity and boom length in order to

carry out the given work scope safely and in accordance
Contractor/Crane supplier
with this procedure.

To control the crane operations as per approved lift plan.

To perform pre-use crane inspections. To maintain crane
operation logbook comprising manuals, pre-use inspection
Crane Operator
lists, crane/lifting gear certificates, wire rope certificate and
hook block certificate.

iii. Lifting Planning and Execution

 Defining the Lift

When a lifting operation has to be carried out, it has to be checked if this particular
lifting operation has been carried out before on that site. A risk assessment and Lift

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
 Plan might already exist. If a risk assessment and Lift Plan do exist then they shall be
assessed to confirm that they are still applicable (e.g. changes to personnel,
equipment, and site layout or work environment could all result in the need for
reassessment of hazards). Assuming that significant changes have not taken place
then lifting operations may proceed under the requirements of the Lift Plan subject
to approval by the lifting engineer. If the lifting operations have not been carried out
before, a competent person will prepare a Lift Plan. This has to be initiated by the
executing department. To define the lift the following parameters are established:

•
Load weight, shape, center of gravity and availability of adequate lifting
points
• Initial and final load positions and how it will get there
• The environment in which the Lifting Equipment will be use
 Planning

➢ Risk Assessment

For every lifting operation the risks have to be assessed and controlled.

As part of the Hazard Effect, a risk assessment is carried out prior to any lifting
operation to identify associated hazards, their severity and likelihood of occurrence.
The ‘Risk Assessment Matrix’ (RAM) for determining risk is shown in Attachment No.
11.2 and is the basis of the risk assessment process, with the objective of ensuring
that all tasks have Low Risk through elimination or adequate control. All risk
assessments are formally to be documented. The risk assessment addresses the
following aspects and activities:

• Cultural, communication and language difficulties

• Weight, size, shape and center of gravity of load
• Availability of approved lifting points on load
• Method of slinging/attaching/detaching the load • Overturning/load
integrity/need for tag lines
• Suitability and condition of Lifting Equipment to be used • Initial and final
load positions and how it will get there
• Ground and underground considerations
• Lifting over live equipment
• Number and duration of lift(s)
• Conflicting tasks in area
• Environmental conditions including weather and permissible limits
• Lighting in the pick-up and lay-down areas
• Proximity hazards, obstructions, path of load (e.g. potentially live electrical,

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 hydraulic or pneumatic lines, underground conduits, bridges and overhead
structures)
• Working under suspended loads
• Access and emergency escape routes for the Lifting Appliance Operator and
load handlers (e.g. Banks man, Slinger)
• Experience, competence and training of personnel
• Number of personnel required for task
• Pre-Use Inspection of equipment by Operator
• Visibility of the load at all times by either the Lifting Appliance Operator or
the person guiding the load (Banks man). He must maintain communication
with the Operator at all times either via hand signals, radio or a relay Signal
Banks man
➢ Routine Lifts:

This classification comprises:

• Routine crane operations

• Repetitive lifting operations using the same equipment (eg drilling activities),
and
• Routine lifting operations with Loose Lifting Equipment

A generic risk assessment and Lift Plan may be used for Routine Lifts. However,
classifying a lifting operation as ‘routine’ does not automatically make it a ‘safe’
lifting operation – most incidents associated with lifting occur during routine
operations. The risk assessments and Lift Plans shall always be reviewed during the
Toolbox Talk for continued applicability.

➢ Non-Routine Lifts:

Non-routine lifting operations can be further sub-divided to reflect increasing risk:

•
Simple lifting operations using Loose Lifting Equipment
•
Complicated lifting operations eg tandem lifting
•
Complex / Critical / Heavy lifting operations requiring a Lift Plan with
engineering input
 Execution

➢ Communication of Lift Plan

The safety team should ensure that the lilting area is safe & secure. This safety Team
should check the availability of all documents (3rd party certificates, Insurance,

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
 inspection report, etc…) Prior to starting of lifting operations a competent person
shall hold a Toolbox Talk with all personnel assigned to carry out the lift. to the lift
shall be covered during the Toolbox Talk.

The Person-in-Charge (PIC) shall be clearly identified and made known to all
members of the lift team and personnel in the proximity. All personnel involved in
the lifting operation shall have their individual responsibilities clearly allocated. All
personnel should have the opportunity to review the findings of the risk assessment
and the details of the Lift Plan to ensure that everyone clearly understands and
agrees with the methods and control measures to be used.

➢ Conducting the Lifting Operation

Lifting operations shall l be conducted in strict accordance with the approved Lift
Plan any variation from the agreed Lift Plan shall result in the job being stopped and
reassessed to ensure continued safe operation The Lifting Appliance Operator shall
obey an emergency stop signal at all times, no matter who gives it. When lifting
operations need to be controlled by signals, a designated signal person shall be
assigned. Signals between the Lifting Appliance Operator and the designated signal
person (Banks man / Signaler) shall be audible or visible at all times (two-way radios
to be supplied). The appropriate load-radius chart for the Lifting Appliance
configuration in use shall be visible to the operator. Load to be lifted shall be
confirmed to be within the rated capacity of the Lifting Equipment and attached by
means of suitable Lifting Accessories. The Operator of the Lifting Appliance shall not
leave the operating controls while the load is suspended.

➢ Moving the Load

• Prior to lifting the PIC shall be satisfied that the load is secure and properly
balanced and that the load path is clear of obstructions and personnel
• At commencement of the first lift the Lifting Appliance Operator shall
carefully check the operation of the hoist brake to ensure no slippage occurs
• Take up sling slack to confirm that the Lifting Appliance hook has been
positioned centrally over the load lifting point, adjust the Lifting Equipment as
necessary to minimize any ‘drift’ of the load as it is lifted
• No external forces shall be applied to the load that create significant side
loading of the Lifting Equipment
• For crane operations appropriate tag lines shall be used to control the load–
large or long loads with flat sides that could act as a ‘sail’ are particularly
prone to spinning and tag lines shall be used – tag lines shall be secured to
the load and not to the rigging slings
• Cranes shall not be used for dragging a load Additional requirement, specific

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
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 to particular equipment or operations, are detailed in Appendix-3
➢ Reacting to changing Conditions

All critical lifting parameters (e.g. weather, sea state, visibility, terrain stability and
slope, surrounding operations and installations, site access and egress, Lifting
Equipment, personnel) shall be identified during the risk assessment and preparation
of the Lift Plan the PIC shall ensure that these conditions are monitored as lifting
operations proceed to ensure continued safety.

If, as part of the operation and maintenance of equipment, the computer system
shuts down the operation, the load must be placed on the ground and a new lift plan
must be developed, eliminating the condition that caused the shutdown. Procedures
for recovering and landing the load in the event of the lift being aborted shall be
clearly identified.

➢ Learn and Record

After completing the lifting operation, everyone involved in the lift should have the
opportunity to discuss and make improvements to the Lift Plan. Any learning points
noted on the plan must be reviewed by a competent person and, where appropriate,
action taken. Learning points may include feedback on equipment effectiveness,
lifting techniques, personnel, etc. (See risk Assessment sheet for lifting works
Attachment No-11.2)

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
Tel. + 966 12 6616191, Fax + 966 12 2610481 Ext. 106
 10. ATTACHMENTS

11.1 RISK ASSESSMENT FOR MICROTUNNELING WORKS

11.2 RISK ASSESSMENT MATIX FOR LIFTING WORKS
11.3 JOB SAFETY ANALTSIS FOR MICROTUNNELING WORKS

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SAUDI TUNNELING COMPANY for CONTRACTING (STCC)
P.O. Box 16116, Jeddah – 21464, KSA
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 11.1 RISK ASSESSMENT For MT works
REDUCED
TASK HAZARD HAZARD EFFECT ( CONSEQUENCE ) C L RISK MITIGATED BY C L ALARP
RISK

110v equipment, regular checks on cable, connector and service.

Cable protection and careful routing. Examination by electrician of
Electricity. Death/shock. 5 4 20 3 2 6 Yes
all tools brought to site before authorisation for use. Isolations
under PTW

Establish pedestrian routes, fit heavy plant with reversing

Vehicle
Serious injury to personnel. 4 4 16 indicators/warning sirens and CCTV if necessary. Tail marking via 2 2 4 Yes
movement.
reflector strips. High vis clothing worn by all operatives.

Lifting control by ‘appointed person’/ supervisor, competent rigging

Fall of material, serious injury, following lifting plan and method statement. Barrier lift and
Lifting. 5 4 20 3 2 6 Yes
equipment and asset damage. laydown areas. Inspection of equipment to ensure LOLER
compliance.

Trained personnel wearing harnesses when working at height if as

Work at
Fall from height/ death. 5 4 20 a first action area protection from installed walkways and/or 3 2 6 Yes
height.
scaffolding and netting /air bags cannot be deployed.

Good housekeeping, avoidance of trailing cables, use of correct

Slips and trips. Minor injury. 2 3 6 2 2 4 Yes
storage of tools and equipment.
GENERAL ACTIVITES

Mandatory eye protection and correct PPE at all times. No working

Dust. Eye injuries and skin irritation. 2 3 6 2 1 2 Yes
in shorts and bare tops.

Flying Moderate injury to skin, serious eye

4 3 12 Correct PPE at all times 3 2 6 Yes
particles. injuries.

Observe confined space controls and permit conditions.

Emergency arrangements in place and communicated. Gas
Confined Collapse of personnel due to fumes monitoring and working BA if oxygen deficiency and /or toxic
5 4 20 2 3 6 Yes
spaces. or lack of oxygen; fire and explosion. fumes foreseeable. Escape sets if no BA deployed. TBT
To observe the toxic fumes we are using Gas detection
To remove the above toxic gases we are using Blowers

Overhead Height gauging at site entrance and in front of any other height
Serious injury and plant damage. 4 3 12 4 2 8 Yes
obstructions. restriction.

Vehicles Serious injury following unauthorised

4 4 16 No unauthorised use, daily checks by certificated operator 2 2 4 Yes
operations. use

Competent COSHH assessment and clearly defined criteria for

acceptance, filing of document and MSDS. Correct storage and
Substances. Poisoning, burns, irritations.Fire 3 3 9 3 2 6 Yes
instructions for use. Flammables and dangerous substances are
to be assessed under the same regime.

Page 1of2
RISK ASSESSMENT SHEET

Criteria (C) Consequence: Criteria ( L ) Likelihood: Risk Conclusions: Working on

Negligible- immediate Improbable- so unlikely Calculator, construction sites is a hazardous
return to work that it would activity if the controls proposed
Minor - first aid and not happen. Risk level R= are followed this environment
return to work. Unlikely- remote
chance of event
CXL can be successfully managed.
Moderate- medical
treatment/ lost Possible- inattention
time may cause an 1-4
Major- multiple event to Acceptable
injuries and happen. 5-8
RIDDOR Probable- highly likely Tolerable Overall risk (High Medium or
reportable without 9-10 Low)
control. Moderate
Fatal/Catastrophic- Death, Certain- will happen 12-15 Are risks reduced to ALARP (as
loss of without
Intervention
Substantial low as reasonably practicable).
installation / control. >15 Yes
Intolerable

Likelihood→ Improbable Unlikely Possible Probable Certain

Consequence↓ 1 2 3 4 5
Negligible 1 1 2 3 4 5
Minor 2 2 4 6 8 10
Moderate 3 3 6 9 12 15
Major 4 4 8 12 16 20
Fatal/catastrophic 5 5 10 15 20 25

Overall risk.
1-4 =Low; 5-10 = Medium; 12-25=High

Page 2 of 2
 11.2 Risk Assesment Matrix for Lifting Works
Identified Risk
Hazards
Interaction with public highway
and members of the public.
Interaction with other site
Access to and
operations and operatives.
Egress from
Interaction with delivery
Site
vehicles.
Risk to: Public/ Operators/ Site
Operatives
Crane travelling over
unprepared or uneven ground
possible damage to ground
surface and or crane and
Ground
property. Ground collapse
Conditions
beneath outriggers causing
possible overturning Risk to:
Public/ Operators/ Site
Operatives
Damage to sub-surface service
lines causing possible flooding,
explosion, asphyxiation or
Underground electrocution. Risk to: Public/
Services Operators/ Site Operatives
Crane positioned incorrectly for
required lift. Possible damage to
crane or property during set up
or de-rig procedure. Risk to:
Public/ Operators/ Site
Crane Positioning
Set up Procedure Operatives
De-rig Procedure
Crane operation, causing
damage to property or injury to
personnel. Mechanical
breakdown or structural
Plant
Operations damage. Risk to: Public/
Operators/ Site Operatives
Risk
Prevention Measures Managed
Risk rating
High Banksman with hi-vis to control traffic
and public while crane manoeuvring
Medium into site Flashing amber lights and
audible alarms when reversing.
Site management to be aware of low
Low
intended route on site.
All other site operatives to be made
N/A aware of crane movement.
High Ground to be assessed at time of site
inspection. Ground improvement to
be implemented where needed.
Medium
Operator/Crane Supervisor to inspect
on day of operation. Outrigger pans to low
Low
be used with additional heavy duty
mats where needed. Client to inform
N/A the crane company of any known risks
High A full assessment and mapping of the
travelling and working area of the
crane will be made at the site
Medium inspection. The Site Manager to make
the crane operator aware of any low
Low known risk. Permit to work in place
where applicable. Operator/ Crane
Supervisor to check on day of
N/A
operation for any new or unseen risks
Crane working position clearly
High
identified in Method Statement
drawings and made known to crane
operators and marked out where
Medium required. Crane manufacturer’s
instructions for set up and de-rig low
procedure followed. Only trained and
Low
competent personnel to operate and
assist with rigging. No one but lift
associated personnel within crane set
N/A
up area.
High Trained, certified and competent
crane operators. Cranes fully
maintained with full service and
Medium testing history. Manufacturer’s
instructions adhered to at all times. low
Low
N/A
Page 1of3
 Incorrect slinging of loads
Unsuitable lifting equipment
used. Failure of lifting
Manual Handling equipment. Incorrect signals
Sling of Loads
give to crane operator causing
Signalling Tailing damage to loads, property or
Operations injury to personnel. Crane
Multiple Crane operator lifting unseen loads.
Operations Risk to: Public/ Operators/ Site
Operatives
Injury to public or site personnel
from falling objects or materials.
Damage to vehicles or property
Protection of during lifting operations. Risk
from suspended loads.
Public & Site
Risk to: Public/ Operators/ Site
Operatives
Operatives
Falling
Objects
Damage to property or plant.
Risk of responsibility for
collision or injury. Protection of
personnel during works.
Traffic Risk to: Public/ Operators/ Site
Pedestrian Operatives
Management
Adverse
Weather Crane operation, load stability
Conditions and control. Risk of injury to
personnel and damage to
property. Risk of lightning strike.
Bad visibility.
Risk to: Public/ Operators/ Site
Operatives
Overhead or Damage to crane or property if
slewing crane boom or superstructure
Obstructions or comes into contact with any
Restrictions restriction. Infringement of
Low Headroom unauthorised air space. Working
in restricted work space.
Risk to: Public/ Operators/ Site
Operatives
High Trained, certified and competent
Slingers to sling all loads. Only
specified lifting tackle and lifting
tackle with current and valid
Medium
certification to be used. Visual
inspection to be carried out on all low
lifting tackle prior to use. Qualified
Low
Signallers to use recognized hand
signals or radio commands to
communicate with crane operators.
N/A
Radios used for unsighted lifts.
Work area to be cordoned off as an
High
exclusion zone. Sufficient barrier &
signage to be in place to warn non lift
associated persons of overhead &
Medium ground level risks. All over-sail to be
addressed, monitored and evacuation low
implemented where practicable. Lift
Low crew to be aware of all lifting
operations.
N/A
High Full assessment of required
restrictions on public highways,
service roads or private roads to be
Medium made at site inspection. Any Traffic
Management contractors supplied by
site or the crane company will be fully low
Low certified and competent. Traffic
Management supplied by the site
should be set up prior to arrival of
N/A
crane.
High Weather reports obtained before and
during lifting operations. Crane
operator to monitor wind speed
Medium equipment. Suspension of lifting
operation until risk subsides. low
Low
N/A
High Full assessment of any risks made and
addressed at site inspection. Safe
system of work adhered to where
Medium implemented. Work to zone alarms
where implemented. Implement low
Low crane swl computer working
restrictions. All relevant authorities
contacted and advised and any
N/A restrictions adhered to.
page 2 of 3
Risk Assessment

Specific to lifting and hoisting operations:

Low Risk: May be acceptable but review task to see if risk can be reduced further.

Medium Risk: Task should only be undertaken with appropriate management

Authorization after consultation with specialist personnel and assessment team.

Where possible, the task should be redefined to take account of the hazards

Involved or the risk should be reduced further prior to task commencement.

High Risk: shall not proceed. It should be redefined or further control measures put in

Place to reduce risk. The controls should be reassessed for adequacy prior to

Task commencement.
 11.3 Job Saftey Analysis For MT works
Job Description Location / Activity
Lift Plan lifting equipment
lifting equipment and put it in
Surface Setup
the proper place on surface area
setup equipment and put it in
Shaft Setup
the proper place inside shaft
to do all nesssary connection (
Equipment Connection hydrolic , electric, hoses ) during
mico tunnling works
fabrication or process that joins
welding works materials - ( metals) during micro-
tunnling works
remove material from the
Cutting works workpiece to make it useable
during micro-tunnling works
When a full length of
concrete casing pipe is
jacked into the ground, new
pipes are positioned into
pipe installation
the frame, jointed to the
pipe string and then
pushed forward.
Hazards Recommendations
1-Crane should have Vehicle Registration/Inssurance
2-Crane should have a Valid TUV Certificate
3-Crane Operator Should have Heavy Vehicle Licesnse
Struck by equipment /Falling & 4-Crane Operator Should have valid TUV certificate
serious enjuries 5-there should be one person to guide the crane operator
during any lifting activity
1- Make sure that during setup equipment in the proper
place and lifting the equipment the lifting hook properly
placed at specific point of the equipment
2-Make sure that there should be one person one person
on surface to guide the crane operator.
3-Make sure that vehicles /equipment do not enter the
Struck by equipment
area where the surface setup activityis being
undertaken.
4-Barricading / Safety Cones to be used to identify
safepassages for personnel and equipment.
1.Make sure that during lower the equipment the lifting
hook properly placed Around pipe
2.Make sure that there should be one person inside the
Struck by equipment shaft and one person out side the shaft to guide the
crane operator
1-All electrical cords shall be inspected and in good
working condition prior to use (no missing ground pins,
Electric Shock no damaged cords, or frayed wires evident) And proper
struck by hoses insullation
2- make sure during lifting hoses crane belt tie good
enough around
1- When practical, the object to be welded, or heated
should be moved to a designated safe location away from
flammable liquids and other combustibles
2- dry chemical extinguisher must be immediately
available in the work area and must be maintained in a
state of readiness for instant use immediately available in
Fire the work area and must be maintained in a state of
Eye Damage readiness for instant use.
Cuts 3-Welding operations shall be performed by trained
Burns 4-During welding operations, proper welding gloves and
a full-face mask , shall be worn to prevent
injuries to the operator
5-There must be a working blower inside the welding
zone area
1-When practical, the object to be cutted , or heated
should be moved to a designated safe location away from
flammable liquids and other combustibles
2- dry chemical extinguisher must be immediately
available in the work area and must be maintained in a
Fire state of readiness for instant use immediately available in
Eye Damage the work area and must be maintained in a state of
Cuts readiness for instant use.
Burns 3-cutting operations shall be performed by trained
4-During welding operations, proper welding gloves and
a full-face mask , shall be worn to prevent injuries to the
operator
1-Make sure that during lower the pipe the lifting hook
properly placed Around pipe
2-Make sure that there should be one person inside the
Struck by pipe being unloaded shaft and one person out side the shaft to guide the
in to the shaft crane operator