556JACK AND BORE

556-1Description

556-1.1Scope of Work: The work specified in this Section documents the approved

construction methods, procedures and materials for Jack and Bore (J&B), also known as auger boring. Micro tunneling (MT) is also included in the category of J&B for purposes of the Specifications.

556-1.2General: J&B is a method for installing a product (often called a casing) that

may serve as a direct conduit for liquids or gases, or as a duct for carrier (Pipe, cable, or wire line products). It is a multi -stage process consisting of constructing a temporary horizontal jacking platform and a starting alignment track in an entrance pit at a desired elevation. The product is then jacked by manual control along the starting alignment track with simultaneous excavation of the soil being accomplished b y a rotating cutting head in the leading edge of the product’s annular space. The ground up soil (spoil) is transported back to the entrance pit by helical wound auger flights rotating inside the product. J&B typically provides limited tracking and steerin g as well as limited support to the excavation face. MT is conducted similar to J&B with the exception that it is remotely controlled, guided pipe jacking process that provides continuous support to the excavation face. The guidance system usually consis ts of a laser mounted in the tunneling drive shaft which communicates a reference line to a target mounted inside the MT machine’s articulated steering head. The MT process provides the ability to control the excavation face stability by applying mechanica l or fluid pressure to counterbalance the earth and hydrostatic pressures. Removal and disposition of excess material varies, is the responsibility of the boring contractor and is not covered under this Specification. However, the cost of removal or final disposition is included in the cost of the J&B operation. No J&B conduit may be left open ended without approval of the Engineer .

556-2Materials

Select materials approved for installation within the right -of-way based on their suitability for the co nstruction method as defined in Table 556-1. After determining product suitability, individual material standards as contained in Table 556-2 apply.

Table 556-1 Product Suitability by Construction Method Type Pipe/Casing Installation Mode Suitable Pipe/C asing Jack and Bore Jacking Steel, Plastic Micro tunneling Jacking DI, FRPM, PC, PCCP, RCCP, RCP, Steel

784 FY 2023-24 Return to Table of Contents Table 556-2 Material Standards Acceptable for J&B and MT Installations Material Type Non-Pressure Pressure Ductile Iron (DI) AWWA C150/C151 ASTM A716 AWWA C150/C151 Fiberglass Reinforced Polymer Mortar (FRPM) ASTM D3262 ASTM D3517 AWWA C950 Polymer Concrete (PC) DIN 54815-1 & 2 N/A Prestressed Concrete Cylinder Pipe (PCCP) N/A AWWA C301 Reinforced Concrete Cylinder Pipe (RCCP) N/A ASTM C361 Reinforced Concrete Pipe (RCP) ASTM C76 ASTM C361 AWWA C300/C302 Steel ASTM A139 Grade B(1) API 2B(2) AWWA C200 API 2B(2) Polyvinyl Chloride (PVC) ASTM D1785 ASTM D1785 Reinforced Thermosetting Resin Pipe (RTRP) ASTM D2996 or ASTM D2997 ASTM D2996 or ASTM D2997

Unless otherwise tested and approved by the Department, only use encasement pipe or uncased carrier pipe material that is new and has smooth interior and exterior walls. When the Plans show that the casing is to be used as a drainage carrier pipe, extend the casing the entire length from drainage structure to drainage structure. When using uncased carrier pipe, use pipe meeting the req uirements in 556-4.3. Maintain a uniform diameter, wall thickness and material type for the entire length of the casing.

556-2.1Steel Pipe Casing and Welds: In addition to meeting or exceeding the

conditions contained in Table 556-1 and Table 556-2, meet the following requirements:

largest outside diameter of the carrier. Casing size must accommodate pressure pipe or carrier pipe joint restraints.

seamless pipe.

recommended minimum nominal wall thicknesses to meet the greater of either installation, loading or carrier requirements.

which are compatible with the J&B equipment. Use steel pipe casings and welds meeting or exceeding the thickness requirements to achieve the service life requirements noted in the Department Drainage Manual Chapter 6. For purposes of determining service life, ensure that casings installed under roadways meet or exceed cross drain requirements and casings under driveways meet or exceed side drain pipe requirements. For pipe used in drainage applications, use pipe meeting the requirements in 556-4.3. For purposes of material classification, consider steel pipe casing structural plate steel 785 FY 2023-24 Return to Table of Contents pipe. Ensure that steel pipe casing of insufficient length achieves the required length through fully welded joints. Ensure that joints are air -tight and continuous over the entire circumference of the pipe with a bead equal to or exceeding the minimum of either that required to meet the thickness criteria of the pipe wall for jacking and loading or service life. All welding shall be done in accordance with the Amer ican Welding Society Structural Welding Code - Steel D1.1.

556-2.2Reinforced Concrete Pipe Casing: In addition to meeting or exceeding the

conditions contained in Tables 556 -1 and Table 556 -2, meet the following requirements: Ensure that concrete pipe c omplies with the following minimum requirements:

are permanently secured together by welding in place

wall

wall

4.3. Upon installation, the Engineer may, at his discretion, require the Contractor to perform concrete wiping or injection of the joints if it is believed the joints have not maintained their water tightness during the jacking operation. No additional paym ent will be made for this operation.

556-2.3Plastic Pipe Casing : Plastic pipe may be jacked and bored if its physical

properties meet or exceed the conditions contained in Tables 556 -1 and 556 -2, and has a sufficient wall thickness to maintain proper ali gnment without exceeding the deflection requirements in Section 430 -9.3. If plastic pipe is Jacked and Bored it may not be used as a pressurized carrier. Plastic pipe casing installed by the jack and bore method requires the use of an auger. Open end jacki ng without the use of an auger for continuous cleanout of the bore as the pipe is advanced is not permitted. Closed end jacking is not permitted. For drainage applications, use pipe meeting the requirements in 556 -4.3.

556-2.4Pipe Couplings and Joints: In addition to meeting or exceeding the conditions

contained in Tables 556 -1 and 556 -2, to minimize potential for bore failure, couplings must not project at right angles from the casing diameter by more than 3/4 inch.

when the coupling thickness is less than the casing thickness.

Couplings must have a full bead weld such that the thickness, when measured at an angle of 45 degrees to the casing and coupling interface, must be no less than the casing thickness.

786 FY 2023-24 Return to Table of Contents

established for the casing material to which they are being attached.

jacking. All chemical welds must be completely set and cured before any jacking is attempted.

556-3Constructi on Site Requirements

556-3.1Site Conditions:

any other excavation as specified in Section 120. When using auger fluids, the sump pits must contain auger fluids if vacuu m devices are not operated throughout the boring operation.

the work site is cleaned of all excess auger fluids or spoils. Removal and final disposition of excess fluids or spoils is the responsibility of the boring contractor and ensure that the work site is restored to pre -construction conditions or as identified in the Plans.

Plans.

MUTCD when and where the former is silent.

taking the necessary precautions of proper signing and Mainte nance of Traffic Operations.

556-3.2Ground Water Control: Investigate all sites for possibility of having to manage

groundwater problems that may occur due to seasonal changes or natural conditions. When ground water level must be controlled, use a sys tem and equipment that is compatible with the properties, characteristics, and behavior of the soils as indicated by the soil investigation report.

556-3.3Damage Restoration: Take responsibility for restoring any damage caused by

heaving, settlement, sep aration of pavement, escaping boring fluid (frac -out) of the J&B or MT operation at no cost to the Department. 556-3.3.1 Remediation Plans: When required by the Engineer, submit detailed plans which show how damage to any roadway facility will be remedie d. These details will become part of the As -Built Plans Package. Remediation plans must follow the same guidelines for development and presentation of the As -Built Plans. When remediation plans are required, they must be approved by the Engineer before any work proceeds.

556-4Quality Control

556-4.1General: Take control of the operation at all times. Have a representative who is

thoroughly knowledgeable of the equipment, boring, and Department procedures present at the job site during the entire install ation and available to address immediate concerns and emergency operations. Notify the Engineer 48 hours in advance of starting work. Do not begin the installation until the Engineer is present at the job site and agrees that proper preparations have been made.

556-4.2Construction Process and Approval: For all installations, submit sufficient

information to establish the proposed strategy for providing the following:

line and grade and the intervals for checking line and grade. Indication may be provided by using a water gauge (Dutch level) or electronic transmitting and receiving devices. Other methods must have prior approval. Maintain a record of the progress at the job site. 787FY 2023-24Return to Table of Contents

the equipment manufacturer’s information for all power equipment used in the installation.

of the casing by more than 1/3 times the casing diameter and in stable cohesive conditions not to

exceed 8 inches.

materials, the cutting head is retracted into the casing a distance that permits a balance between

pushing pressure, pipe advancement and soil conditions.

removal relative to the advancement of the casing.

technique.

strength in loose unstable materials when the cutting head has been retracted into the casing to

reduce skin friction as well as provides a method for the slurry lubricant to coat the outside of the

casing.

Subsequent auger size may be reduced, but the reduced auger diameter must be at least 75% of

the full auger diameter.

injection shall be no closer than 2 feet from the leading edge of the casing.

556-4.3Testing:

556-4.3.1 Testing Requirements: Ensure all casing joints meet the Department’s

watertight pressure requirements in accordance with Section 430. Testing may consist of one of

the following methods but must always meet or exceed Department testing requirements.

requirements set by the owner. If the owner does not require pressure testing, the Engineer may

require at least one test.

556-4.3.2 Drainage Application Testing (Under Pavement): When under

pavement (including sidewalk) and shoulders, all J&B pipe installations must meet or exceed the

Department’s watertight pipe and joint configuration in accordance with Section 430. The

Engineer will determine when and where watertight joint requirements shall be applied to the

ultimate roadway section for future widening. For all J&B carrier pipes installed without casing

under pavement, perform air pressure testing at 5 psi in the presence of the Engineer as follows.

source. Record pressure loss for 6 hours. A pressure loss equal to or less than 0.5 psi is

acceptable. or,

pressure drops of 1/2 psi for a time period recommended by the manufacturer.

If the pressure loss exceeds 0.5 psi, repair leaks using methods approved by the Engineer and

retest. 788FY 2023-24Return to Table of Contents

556-4.3.3 Drainage Application Testing (Not Under Pavement): When J&B

pipe installations are not located under the pavement, the pipe and joint configuration must meet

or exceed soil tight joint requirements. The test for a soil tight joint allows up to 0.1 gallon of

water leakage at a sustained pressure of 2 psi. Conduct test for joint integrity for one hour.

556-4.3.4 Damaged Product Testing: When there is any indication that the

installed product has sustained damage and may leak, stop the work, notify the Engineer and

investigate damage. The Engineer may require a pressure test in accordance with 556-4.3.2.

Perform pressure test within 24 hours unless otherwise approved by the Engineer. Submit the test

results to the Engineer for review and approval. The Engineer shall be allowed up to 72 hours to

approve or determine if the product installation is not in compliance with Specifications. The

Engineer may require non-compliant installations to be filled with excavatable flowable fill at no

cost to the Department.

556-4.4Product Locating and Tracking: Install all facilities such that their location can

be readily determined by electronic designation after installation. For non-conductive

installations, attach a minimum of two separate and continuous conductive tracking (tone wire)

materials, either externally, internally, or integral with the product. Use either a continuous green

sheathed solid conductor copper wire line (minimum No. 12 AWG for external placement or

minimum No. 14 AWG for internal placement in the conduit/casing) or a coated conductive tape.

Ensure that conductors are located on opposite sides when installed externally. Connect any

break in the conductor line before construction with an electrical clamp or solder, and coat the

connection with a rubber or plastic insulator to maintain the integrity of the connection from

corrosion. Clamp connections must be made of brass or copper and of the butt end type with

wires secured by compression. Soldered connections must be made by tight spiral winding of

each wire around the other with a finished length minimum of 3 inches overlap. Tracking

conductors must extend 2 feet beyond bore termini. Conductors must be tested for continuity.

Identify each conductor that passes by removing the last 6 inches of the sheath. No deductions

are allowed for failed tracking conductors. Failed conductor ends must be wound into a small

coil and left attached for future use.

556-4.5Augering Fluids: Use a mixture of bentonite clay or other approved stabilizing

agent mixed with potable water with a minimum pH of 6.0 to create the drilling fluid for

lubrication and soil stabilization. Vary the fluid viscosity to best fit the soil conditions

encountered. Do not use other chemicals or polymer surfactant in the drilling fluid without

written consent of the Engineer. Certify in writing to the Engineer that any chemicals to be added

are environmentally safe and not harmful or corrosive to the facility. Identify the source of water

for mixing the drilling fluid. Approvals and permits are required for obtaining water from such

sources as streams, rivers, ponds or fire hydrants. Any water source used other than potable

water may require a pH Test.

556-4.6Micro-Tunneling (MT) and Micro Tunnel Boring Machine (MTBM)

Requirements:

556-4.6.1 Performance Requirements: The MTBM must meet the following

minimum performance requirements:

MTBM type.

horizontal direction to a tolerance of plus or minus 1 inch from design alignment.

789FY 2023-24Return to Table of Contents

the cutter head or by using anti-roll fins or grippers. The Engineer must approve other methods.

being jacked.

For slurry systems, the following is also required:

the slurry loop.

556-4.7Failed Bore Path: If conditions warrant removal of any materials installed in a

failed bore path, as determined by the Engineer, it will be at no cost to the Department. Promptly

fill all voids by injecting all taken out of service products that have any annular space with

excavatable flowable fill.

556-5Jack and Bore and Micro-Tunneling Operations

556-5.1Installation Process: Provide continuous pressure to the face of the excavation

to balance groundwater and earth pressures. Ensure that shafts are of sufficient size to

accommodate equipment, the pipe selected and to allow for safe working practices. Provide entry

and exit seals at shaft walls to prevent inflows of groundwater, soil, slurry and lubricants. Use

thrust blocks designed to distribute loads in a uniform manner so that any deflection of the thrust

block is uniform and does not impart excessive loads on the shaft itself or cause the jacking

frame to become misaligned.

The jacking system must have the capability of pushing the pipe in J&B

operations or MTBM and pipe for MT operations through the ground in a controlled manner and

be compatible with the anticipated jacking loads and pipe capacity. Monitor the jacking force

applied to the pipe and do not exceed the pipe manufacturer’s recommendations.

Ensure that the pipe lubrication system is functional at all times and sufficient to

reduce jacking loads. Use pipe lubrication systems that include a mixing tank, holding tank and

pumps to convey lubricant from the holding tank to application points at the rear of the MTBM.

Maintain sufficient fluids on site to avoid loss of lubrication.

Power Distribution System must be identified in the Plans package or permit

provisions as well as any noise constraints. Identity spoil removal capability and method to avoid

creating hindrance to other activities which may be necessary in the area.

556-5.2Excess Material and Fluids: Monitor the pumping rate, pressures, viscosity and

density of the boring fluids to ensure adequate removal of soil cuttings and the stability of the

borehole. Contain excess drilling fluids, slurry and soil cuttings at entry and exit points in pits

until they are recycled or removed from the site.

Ensure that all boring fluids and other materials are disposed of or recycled in a

manner acceptable to the appropriate Federal, State, and Local Rules and Regulations. When

jacking and boring in known or suspected areas of contaminated groundwater or soil, coordinate

with the Engineer and District Contamination Coordinator (DCIC) during the pre-construction

meeting and prior to the start of boring to determine the best course of action for J&B activities

within the contaminated area. If the J&B operation encounters an unidentified area of

contamination or abnormal condition indicating the presence of potentially contaminated

material, stop operations and contact the Engineer immediately. Do not continue boring without

the Engineer’s approval. 790FY 2023-24Return to Table of Contents

556-5.3Boring Failure: If an obstruction is encountered which prevents completion of

the installation in accordance with the design location and Specifications; the pipe may be taken

out of service and left in place at the discretion of the Engineer. Immediately fill the product left

in place with excavatable flowable fill. Submit a new installation procedure and revised plans to

the Engineer for approval before resuming work at another location. If damage is observed to

any property, cease all work until a plan of action to minimize further damage and restore

damaged property is submitted and approved by the Engineer.

556-6Documentation Requirements

556-6.1Boring Path Report: Submit a bore path report to the Engineer within 14 days

of the completion of each bore path. No payment will be made for directional boring work until

the bore path report has been delivered to the Department. Include the following information in

the report:

when assigned.

structure within the project right of way).

boring location and subsurface conditions as defined in bore path plans below. Reference the

shown plan elevations to a Department benchmark when associated with a Department project,

otherwise to a USGS grid system and datum or to the top of an existing Department head wall.

556-6.2As-Built Plans: Submit to the Engineer a complete set of as-built plans showing

all bores (successful and failed) within 30 calendar days of completion of the work. As-built

plans must be PDF files, in the same scale as the Plans. Include notes on the plans stating the

final bore path diameter, facility diameter, drilling fluid composition, composition of any other

materials used to fill the annular void between the bore path and the facility or facility placed out

of service. If the facility is a casing, note this, as well as the size and type of carrier pipes to be

placed within the casing as part of the Contract work. Produce the plans as follows:

installed or installed and placed out of service to an accuracy within 1 inch at the ends and other

points physically observed. They show the remainder of the horizontal alignment of the

centerline of each facility installed or installed and placed out of service and note the accuracy

with which the installation was monitored.

a cross-section of the roadway at a station specified by the Engineer, or a roadway centerline

profile. Also show the ground or pavement surface and the crown elevation of each facility

installed, or installed and placed out of service, accurately to within 1 inch at the ends and other

points physically observed. Show the remainder of the vertical alignment of the crown of each

facility installed, or installed and placed out of service and note the accuracy with which the

installation was monitored. On profile plans for bore paths crossing the roadway, show the Plans

stationing. On the profile plans for bore paths paralleling the roadway show the Plans stationing.

If the profile plan for the bore path is not made on one of the Plans, use a 10 to 1 vertical

exaggeration. 791FY 2023-24Return to Table of Contents

with the name of the utility owner and the final bore path. Note the failed bore path as failed bore

path. Also show the location and length of the cutting head and any product not removed from

the bore path.

encountered and physically observed during the subsoil investigation. For all other obstructions

encountered during subsoil investigation or the installation, show the type of material, horizontal

and vertical location, top elevation and lowest elevation observed, and note if the obstruction

continues below the lowest point observed.

556-7Compensation

No direct payment will be made under this Section. Include the cost to perform this

operation in the Contract unit price for the item being installed.

No compensation will be made for failed bore paths, injection of excavatable flowable

fill, products taken out of service or incomplete installations.

No compensation will be made for the pay item associated with the jack and bore until a

bore path report has been submitted to the Engineer. 792FY 2023-24Return to Table of Contents COATING NEW STRUCTURAL STEEL

560-1Description

Coat new structural steel in accordance with the requirements of thisSe ction. Apply the coating system designated in the Contract Documents.

560-2Materials

560-2.1Coating System: Use only coating products and systems meeting the

requirements of Section 975 and listed on the Department ’s Approved Product List ( APL). All components of coating systems must be from the same manufacturer. Use Type M coal tar epoxy coatings meeting the requirements of Section 926 and listed on the Department’s APL for coating of permanent bulkhead sheet piles and H piles.

560-2.2Thinners, Solvents and Cleaners: Use thinners, solvents and cleaners listed on

the coating manufacturer’s product data sheet.

560-2.3Caulking: Use caulks that are paintable, compatible with the coating system and

recommended by the coating manufacturer as part of the coating system.

560-2.4Soluble Salts Test Kit: Measure the soluble salts using methods in compliance

with SSPC -Guide 15, Table 1. Use a fully automated conductivity meter, fiber strip or multi -step patch, cell, or ring. Ensure the test sleeve or cell creates a sealed, encapsulated environment duringion extraction and is suitable for testing all structural steel surfaces.

560-2.5Abrasives: Use properly sized abrasives to achieve the required cleanliness and

anchor profile. Use abrasives meeting the requirements of SSPC -AB 1, Mineral and Slag Abrasives, SSPC -AB 2, Cleanliness of Recycled Ferrous Metallic Abrasives, or SSPC -AB 3, Newly Manufactured or Re -Manufactured Steel Abrasive and do not introduce any contamination that interferes with the coating application and performance. Submit certification to the Engineer that the abrasives used meet the requirements of this Section and do not contain any chlorides and other salts. For non- metallic abrasives, verify compliance with the conductivity and cleanliness requirements of SSPC -AB1. For recycled abrasives, verify compliance with the conductivity and cleanliness requirements of S SPC-AB 2 after each recycling or more frequently if required by the Engineer. Select a sample from each recycling machine in use and conduct the water-soluble contaminant and oil content tests outlined in SSPC -AB 2 at least one time each week or more frequ ently if directed by the Engineer. Conduct the non -abrasive residue and lead content tests as directed by the Engineer. If test results do not meet requirements, notify the Engineer immediately, remove and replace the abrasive, clean the recycling equipmen t, and conduct tests each day to confirm the equipment is functioning properly. Return to the weekly testing interval as directed by the Engineer.

560-2.6Rust Preventative Compound: Use a Class 3 rust preventative compound

meeting the requirements of Military Specification MIL-C-11796C, Corrosion Preventative Compound, Petrolatum, Hot Applied.

560-2.7Storage: Store materials in conformance with the manufacturer’s

recommendations . 793 FY 2023-24 Return to Table of Contents