Jacking pipes

Issue 1

Contents
Jacking pipes The jacking technique (microtunnelling) Benets of pipe jacking Technical Safety Economic Environmental Steel reinforced concrete pipes (SRCP) Benets of reinforced concrete jacking pipes Fixed steel collar pipes Loose steel collar pipes Selection of jacking pipes Vitried clay pipes Features and benets Product range Connection to standard pipes and access chambers Precast solutions Contact information 1 1 2 2 2 2 2 3 3 4 9 10 13 13 15 18 20 21

Humes leads the industry and develops world class jacking pipes ideally suited for use with modern, closed faced microtunnelling systems. We provide a comprehensive range of both steel reinforced concrete and vitried clay jacking pipes. They are available in a variety of sizes, classes and joint types to suit various applications and installation methods. Our jacking pipes are available in the following ranges; Steel reinforced concrete pipe from DN300 to DN3600 and vitried clay pipe from DN150 to DN1200. Reinforced concrete pressure pipes are designed for the combined effects of the external load and internal (in service) pressure. Australian/New Zealand Standard AS/NZS 4058:2007 Precast Concrete Pipes (Pressures and Non-Pressure) gives a minimum requirement for factory test pressure of 120% of working pressure in the pipeline. SteInzeUG KeraMo vitried clay jacking pipes are manufactured and inspected in accordance with European Standard EN 295.

The jacking technique (microtunnelling)

Pipe jacking is a method of tunnel construction where hydraulic jacks are used to thrust specially made pipes through the ground behind a shield machine, from launch shaft to receival shaft. The term microtunnelling is also often used to describe this method of pipe installation. Pipe jacking is used to install conduits below ground for a variety of applications including: sewerage pipelines stormwater pipelines road and rail culverts pressure pipelines as a sleeve pipe for other utility pipelines (water, sewage, and electricity and communication cables) pipe replacement and relining.

Jacking pipes

Jacking pipes

Jacking pipes

Benets of pipe jacking

Technical
Inherent strength of lining. Smooth internal nish giving good ow characteristics. No requirement for secondary lining. Considerably less joints than a segmental tunnel. Prevention of ground water ingress by use of pipes with sealed exible joints. Provision of invert channels in larger pipes to contain the dry weather ow of a sewer in a combined system.

Economic
Less affected by weather condition Less risk of settlement Minimal surface disruption Minimal reinstatement Reduced requirement for utilities diversions in urban areas

Environmental
There are substantial environmental benets to be gained by the use of pipe jacking techniques when compared with the traditional open trench approach:

Safety
Pipe jacking is an inherently safer method than open trench construction or when considering the risks associated with deep, large section, open excavations: Major reduction in man-hours, opportunities for accidents to occur are less with pipe jacking. In busy urban centres, trenchless operation will not interfere with pedestrian and motor trafc movements. There is signicant reduction in the risk of injury as a result of utility strikes and interface with the public. Less risk of settlement.

Typically the trenchless method will reduce the quantities of incoming and outgoing materials, with a consequent reduction in tipping of spoil and quarrying of imported stone ll. This in turn leads to reduced vehicle movements and subsequently less associated disruption. Minimal surface disruption and reinstatement. Trenchless will not harm existing vegetation. Noise, dirt and smell are minimised.
Source: An introduction to pipe jacking and microtunelling design Pipe Jacking Association UK

Figure 1 Typical pipe jacking set up

Detail Intermediate jacking station Rubber rings Timber joint packer Lead pipe (steel can)

Trail pipe

Jacking direction Crane to lower pipes into position

Jacks

Standard pipe Lubrication port

Thrust ring Standard pipe

Jacking direction

Working face with jacking shield

Launch shaft with hydraulic jacks

Intermediate jacking station to assist longer drives

Receival shaft

Jacking pipes

Humes SRCP has a number of concrete properties that inuence long service life. These properties are: Ultimate compressive strength: Humes SRCP compressive strength is usually in the range of up to 60 MPa and above. The strength of the pipe is a result of the materials used in the concrete mix, the mix design, manufacturing techniques and the curing process. Low water absorption, below 4%, due to the density and impermeability of the concrete used and manufacturing process. AS/NZS 4058-2007 species a maximum allowable absorption of 6% for all concrete pipes. A low water/cement (W/C) ratio of below 0.35. The

Humes is Australias leading manufacturer of SRCP. We have a wide range of diameters, lengths and strengths available. Our SRCP has a proven track record and can be custom designed for applications such as drainage, sewage, water supply and irrigation. A milestone was achieved when Humes' DN2100, xed steel collar pipes were jacked 1,030 m without any intermediate shafts on the Northern Pipeline Interconnector Stage 2, SEQ (refer to our case study on this project for further details).

Benets of reinforced concrete jacking pipes

Optimal strength Humes SRCP are manufactured and factory tested for quality to AS/NZS 4058:2007 "Precast concrete pipes (Pressure and Non-pressure)": A concrete pipe is a rigid pipe system that relies mostly on the strength of the pipe and is only slightly dependent on the strength derived from the soil envelope. The inherent strength of concrete pipe can compensate for site problems not designed for, such as construction shortcomings and higher ll heights and trench depths. Concrete pipes are less susceptible to damage during construction, and maintain their shape by not deecting. All concrete pipe strengths are standardised by AS/NZS 4058 Precast Concrete Pipes. Concrete pipes are strength-tested by the manufacturer to proof loads, or test loads, as nominated by the standard for particular diameter and class. Steel reinforcement in concrete pipes adds signicantly to their inherent strength. The steel reinforcement is shaped into cages by automatic cage welding machines. The machines ensure that the reinforcement cages are dimensionally correct and have tight enginereed tolerances.

W/C ratio is considered a trademark for durable concrete pipe, particularly as high compressive strength is related to this criterion. High alkalinity is controlled by cementitious content maintained by a proper mix design, material properties as well as the manufacturing and curing process. Concrete pipe aggregates, both coarse and ne, meet the requirements of AS 2758. Aggregates are a key element in producing quality concrete and in turn, quality pipe.
Source: Concrete Pipe Facts, Concrete Pipe Association of Australasia, www.cpaa.asn.au/concrete-pipe-facts.html

Jacking pipes

Jacking pipes

Steel reinforced concrete pipes (SRCP)

Durable

Fixed steel collar pipes

A wide robust range is available from DN300 to DN3000 inclusive. They are a custom designed reinforced concrete jacking pipe incorporating a single wide jacking face including timber packers, a secure steel collar cast onto the pipe and a exible watertight joint. All these being essential for longer pipe jacks and unstable ground conditions.

Elastomeric seal The elastomeric seal is located with the corrugated steel collar in the S type collar band, factory secured internally to the steel socket band with adhesive. While, in the J type the seal is retained within the accurately formed recess on the pipe spigot. Both unique designs will ensure that the elastomeric seal remains in place in compression even if joint deection occurs. The joint integrity remains intact when subjected to either internal or external hydraulic pressure. A muck ring is tted within the J type joint; limiting the ingress of soil into the joint during jacking. The muck ring will be compressed by the end of the steel collar.

Applications The xed steel collar jacking pipes provides high axial load transfer capacity and a exible watertight joint. This is the ideal jacking pipe for all stormwater, sewerage, sleeve pipe and jacked low pressure pipeline applications.

Watertight joint (External pressure testing) Steel collar types Humes have undertaken external pressure testing of Humes offer two different types of xed steel collars: the S type which is tted into pipes up to DN700 and the J type tted into remaining sizes (mainly from DN800 to DN3000). The steel collar bands are fabricated to high tolerances to ensure optimum joint performance. Both steel collars include a water stop hydro-seal to prevent ingress of water between the band and the concrete pipe wall. Bentonite or grout injection ttings Pipes can be supplied with or without threaded sockets and plugs, which are cast into the pipe wall in locations to meet the project specic requirements for grout and/ or lubrication injection. deected joints with external hydrostatic pressures up to 400 kPa without visible leaks. On this basis, xed steel collar jacking pipes are rated for 250 kPa external pressure for the joint deections shown in Figures 4 and 5 on page 7. Humes can design pipes for higher external pressure ratings if required.

Figure 2 S type joint prole

Figure 3 J type joint prole

Jacking pipes

Inert thermoplastic linings Humes are able to supply the J type steel collar jacking pipes complete with corrosion protection linings (either High Density Polyethylene (HDPE) or Plastiline- Polyvinyl Chloride (PVC)) in accordance with Water Services Association of Australia (WSAA) standard specication WSA113. These linings are a proven method of concrete protection against H2S attack in trunk sewers.

if required by the project designer for isolation of the joint from the pipeline environment (see Figure 21 on page 26). The combination of mild steel collars with internal joint gap sealant can provide a cost effective solution in certain ground conditions. Jacking pipes
5

Intermediate jacking stations Humes have standard designs for intermediate jacking stations and these include trail and lead pipes for all

Secondary sealing recess All J type steel collar jacking pipes are supplied with a recess on the internal pipe ends which allows for locating a exible sealant, applied internally after installation,

diameters DN1000 to DN2000. The arrangement of these pipes at the intermediate jacking station is shown in Figure 1 on page 24.

Table 1 Features and benets Features Elastomeric seal Benet to asset owner Watertight joint Prevents ingress or egress of water and soil surrounding the pipes and allows pressure grouting of the excavated annulus at the completion of jacking (if required). Collar material The designer has many options for the grade of steel to suit the intended design life in the installed environment of the pipe. Generally, mild steel is considered suitable for in-ground conditions and a non-aggressive environment. Permanent seal location The seal remains in place throughout the design life of the pipeline providing a long-term watertight structure under external groundwater pressures or ground movement. Efcient construction Long drives, lower construction costs and less disturbance to above-ground activities. Maintain watertight joint After installation the muck ring protects the rubber ring and the steel collar to maintain watertightness. Additional sealing options The recess is shaped to allow retention of a exible sealant if secondary joint sealing is required. Benet to contractor Flexibility Allows joint rotation without damage to the pipe joint. Watertight joint Lubrication uids are retained in the excavated annulus without loss of uid or pressure. Secure system Steel collar will remain watertight and secured in place during jacking, even in variable ground conditions. Efcient jointing Rapid pipe jointing ensures operational efciency in the jacking pit. Restrained seal Ensures that the seal remains in place during jointing and jacking with external pressure from groundwater or lubrication injection. Long drives The wide face on the pipe end enables transfer of high jacking forces through the centerline of the pipe wall enabling accurate steering and long drives. Maintain watertight joint Prevents ingress of soil into joint during jacking.

Steel collar xed to pipe with in-built water stop

Corrugated collar recess (S type) Deep spigot groove (J type) Single wide jacking face

Muck ring (J type)

Internal joint recess

No spalling Prevents spalling of inside concrete face if the packer is displaced during jacking.

Jacking pipes

Optimal strength Humes xed collar jacking pipes, both with S and J type collar, are designed with steel reinforcement placed for optimal strength, which combined with the strength and durability of Humes concrete pipes, provides an excellent jacking pipe. Steel reinforced concrete jacking pipes are capable of withstanding higher jacking loads.

Jacking design and forces The Concrete Pipe Association of Australasia (CPAA) publication, Jacking Design Guidelines is a recommended guide to calculate and dene jacking forces. The guide can be downloaded by visiting; www.cpaa.asn.au/CPAA-Online-Shop.html Jacking forces and lateral displacement off line and

The jacking load capacity of standard pipes for a range of joint deections is illustrated in Figures 4 and 5 on the following page. Pipes with higher jacking loads and/or joint deections can be designed for specic projects.

level have to be recorded at regular intervals of jacking distance (not exceeding 200 mm or every 90 seconds). Ensure that jacking forces are maintained within the limits specied in Figures 4 and 5 on the following page. If circumstances cause a jacking force/deection combination outside of these limits, hold the jacking operation and contact Humes for assistance.

Jacking pipes

Figure 4 S type jacking pipes deection curves

300

250 Maximum jacking force (tonnes)

200

150

100

50

0 0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

1.10

1.20

1.30

Maximum joint deection (degrees) DN300 DN350 DN400 DN450 DN500 DN600 DN700

Figure 5 J type jacking pipes deection curves

J Series Jacking Pipes 2500 2,500 2250 2,250 2000 2,000

Maximum jacking force (tonnes) Maximum Jacking Force (Tonnes)

1750 1,750 1500 1,500

1250 1,250 1000 1,000 750 750 500 500 250 250

0 0 0.10 0.10

0.20 0.20

0.30 0.30

0.40 0.40

0.50 0.60 0.70 0.80 0.50 0.60 0.70 0.80 Maximum Joint Deflection (Degrees) Maximum joint deection (degrees) DN1200 DN1350 DN1500 DN1650

0.90 0.90

1.00 1.00

1.101.10

1.20 1.20

DN800 DN2700

DN900 DN3000

DN1000

DN1100

DN1800

DN2100

DN2400

DN2500

DN800 DN1650

DN900 DN1800

DN1000 DN2100

DN1100 DN2400

DN1200 DN2500

DN1350 DN2700

DN1500 DN3000

Jacking pipes

Jacking pipes

Table 2 Fixed steel collar pipes dimensions, mass, jacking loads and deections
Swiftlift anchors T

C t Pw Pt Detail D A B

Nominal diameter 300 350 400 450 500 600 700

Internal diameter 'A' (mm) 300 350 400 450 500 600 700

External diameter 'B' (mm) 430 480 540 606 672 774 876

Wall thickness 'T' (mm) 65 65 70 78 86 87 88

Effective length 'L' (mm) 2,400 2,400 2,400 2,400 2,400 2,400 2,400

Min. joint packer 'Pt/Pw' (mm) 3/40 3/40 3/40 3/40 3/40 6/60 6/60

Steel collar Length 'C' (mm) 50 50 50 50 50 80 80 ID 'D' (mm) 412 462 522 588 654 752 854 Thickness 't' (mm) 1.5 1.5 1.5 1.5 1.5 2 2 Pipe mass (kg) 500 550 660 725 1,000 1,190 1,380

Max. jacking load (tonnes) 100 115 135 165 225 240 280

Collar type S S S S S S S

800 900 1,000 1,100 1,200 1,350 1,500 1,600 1,650 1,800 2,100 2,400 2,500 2,700 3,000

800 900 1,000 1,100 1,200 1,350 1,500 1,600 1,650 1,800 2,100 2,374 2,500 2,636 2,972

1,000 1,110 1,220 1,332 1,450 1,626 1,800 1,940 1,974 2,150 2,500 2,783 3,000 3,096 3,472

100 105 110 116 125 138 150 170 162 175 200 204 250 230 250

2,360 2,360 2,360 2,360 2,360 2,320 2,320 2,985 2,320 2,320 2,985 2,985 2,985 2,985 2,985

12/65 12/70 12/75 12/80 12/90 16/90 16/100 16/110 16/110 16/125 16/160 16/175 16/195 16/175 16/195

120 120 120 120 120 160 160 160 160 160 160 175 175 175 175

989 1,099 1,209 1,321 1,439 1,611 1,785 1,911 1,959 2,135 2,481 2,759 2,977 3,073 3,449

4 4 4 4 4 6 6 8 6 6 8 10 10 10 10

1,800 2,100 2,400 2,800 3,300 4,000 4,800 7,500 5,700 6,700 12,050 12,950 16,650 16,150 19,700

500 500 515 565 650 755 840 1,020 925 1,050 1,440 1,485 2,000 1,900 2,220

J J J J J J J J J J J J J J J

Jacking pipes

Humes offer two types of loose steel collar SRCP jacking pipes, butt joint and in-wall joint. They are available from DN300 to DN3000 (standard range DN300 to DN2100). The steel collar is not attached to the pipe (cast with) but rather is tted onto the pipe before installation. The collars can be supplied by either Humes or the contractor.

In-wall joint jacking pipes are available from DN1200 to DN3600 (standard range DN1200 to DN2100). In-wall joint jacking pipes incorporate a concrete socket formed in the wall of the pipe, a rubber ring located on the pipe spigot and timber packers on one or both joint faces (see Figure 7). Applications In-wall joint jacking pipes are an economical viable alternative for typically short length applications where a exible watertight joint is required, however, this type of joint can have limitations in jacking load transfer. A J type pipe should be specied in these situations.

Butt joint pipes Butt joint jacking pipes incorporate a single wide jacking face. External recesses at each end of the pipe allow for a rolled steel collar to be located between adjacent pipes, providing the necessary shear connection (see Figure 6). Applications Butt joint jacking pipes can provide a cost effective solution for typically short length applications where only limited exibility is required and a soil or watertight joint is not required. This pipe is also suited to sleeve pipe applications for road and rail crossings where the annulus between the utility pipeline and conduit is to be lled with grout after installation. Refer to Table 4 Selection of jacking pipes (page 11), which provides a summary of capabilities for each of the different types of jacking pipes for different requirements and applications.

Figure 6 Butt joint prole

Steel collar

Figure 7 In-wall joint prole

Steel collar

Jacking pipes

Jacking pipes

Loose steel collar pipes

In-wall joint pipes

Table 3 Loose steel collar pipe range In-wall joint Nominal diameter Internal diameter External diameter mm DN300 DN375 DN475 DN525 DN600 DN675 DN750 DN825 DN900 DN975 DN1050 DN1200 DN1350 DN1500 DN1650 DN1800 DN1950 DN2100 1,920 2,088 2,220 2,388 1,200 1,500 280 363 438 518 586 653 730 790 875 951 1,026 1,163 1,324 1,452 1,596 1,756 1,930 2,096 362 445 534 616 698 781 864 946 1029 1,111 1,194 1,359 1,524 1,676 1,842 2,006 2,198 2,388 Butt joint Internal diameter External diameter

Notes: 1. Alternative internal diameters (and external diameters) may be available to suit project specic requirements, contact Humes for assistance. 2. Standard range is equivalent to load class 4 pipes. 3. Contact Humes for in-wall joint pipes in this range.

Selection of jacking pipes

The most basic requirements for all jacking pipes is that they must be capable of supporting the excavation (earth and trafc loads), transferring axial load, providing a shear connection between adjacent pipes and joint exibility that allows for each pipe to follow the path excavated in front of the shield.

In addition, jacking pipes may need to prevent ingress of surrounding soil, groundwater, lubricants or grouts and provide a joint capable of withstanding internal pressure in sewerage or pressure pipeline applications. Jacking pipes must meet both the needs of the contractor and asset owner who is usually represented by the pipeline designer. Table 4 opposite provides a summary of the capabilities of each of our types of jacking pipes for different requirements and applications.

10

Jacking pipes

Table 4 Selection of jacking pipes Jacking pipe requirements or application Standard size class Extended diameter range* Incorporation of inert thermoplastic lining External grouting Internal pressure test capability (kPa) Application of internal secondary sealants Sewerage pipelines Stormwater pipelines Road and rail culverts Sleeve pipe applications Asset owners and contractors Length of jacked pipeline (m) External pressure test capability Jacking force transfer Intermediate jacking stations pipes Contractors Open face shields Closed face pressure shields Lubrication along length of pipeline Fixed steel collar S type DN300 DN700 DN800 N/A Suitable for short lengths 90 N/A J type DN800 DN3000 Up to DN3600 Available Ideally suited 150 Suitable Loose steel collar Butt joint DN300 D2100 DN2250 DN3000 DN900 > Not suitable N/A Not suitable In-wall joint DN1200 DN2100 DN2250 DN3600 Available Limited suitability 90 Limited suitability Jacking pipes

Stakeholder Asset owner

Limited suitability|| Ideally suited Ideally suited Ideally suited 0 50

Ideally suited Ideally suited Ideally suited Ideally suited < DN1000: 0 150 DN1000 DN3000: no limit 250 Excellent Available DN900 DN3000 Suitable Ideally suited Ideally suited

Not suitable Limited suitability Limited suitability Limited suitability# 0 50**

Suitable Suitable Suitable Suitable 0 50

90 Excellent N/A Suitable Ideally suited N/A

N/A Good To be provided by contractor Suitable Not suitable Not suitable||||

90 Moderate To be provided by contractor Suitable Limited suitability Limited suitability

Notes: * Refer to Humes for availability. Grout pressures need to be carefully monitored. Test to AS/NZS 4058: 2007. Higher pressures are possible with certain diameters refer to Humes for advice if higher pressures are required. || If corrosive sewage gases are expected consider using vitried clay jacking pipes distributed by Humes. # The butt joint jacking pipe is suitable for short length drives in certain soil conditions if the annulus between the concrete sleeve pipe and the product pipe is grouted. This grout should also ow into the annulus between the sleeve pipe and the excavated ground. Intermediate jacking stations are not available and length is mainly limited by installation equipment. Some pipe jacking contractors may be able to achieve longer lengths of individual drives in certain soil conditions. Refer to jacking pipe contractor for advice for longer drives. The maximum length will be controlled by installation equipment rather than pipe capability. ** Lack of joint exibility largely controls maximum length. This could be extended in certain soil conditions. There is no published test method for external joint testing of reinforced concrete pipes. External pressures due to lubrication or grouting can be well in excess of ground water pressures. |||| For lubrication to be effective, the annulus between the external diameter of the pipe and the excavated soil needs to be lled. The butt joint pipe may not provide an effective sealed joint.

Jacking pipes

11

Load class Jacking pipes, as opposed to pipes laid in open excavations, are subjected to both jacking forces, external earth loads and life loads (permanent loads) and all of these have to be considered when specifying the pipes. The effect of the jacking force on the pipe barrel is small on account of the high compressive strength of the concrete. The joint, however, must be considered because the joint cross-section is smaller, as a rule, than that of the barrel and the jacking force is transferred eccentrically across the joint. The external earth load on the barrel is equal to or smaller than the trench load on a pipe bedded in a trench of same width as the excavation (i.e. the outside diameter of the pipe plus a margin for over-excavation). The jacking method of installation, therefore, is very efcient from an external load point of view since the external earth load is smaller than both trench and embankment load on pipes of the same diameter under the same height of ll.

The higher value is recommended when the annulus between the pipe and ground is grouted. Grouting of this annulus with a suitable cementitious grout is recommended in most installations as any voids could create a drainage path external to the pipeline which in turn could lead to soil erosion, lowering of ground water tables and, in aggressive soil conditions, an increased risk of corrosion of pipe materials. The axial loading from the pipe jacking is not directly included in the selection of the pipe load class. Timber packers are placed between the jacking faces of the concrete pipes to avoid high stresses that could result from direct concrete to concrete contact. The axial load capacity of the concrete pipe is determined based on the minimum pipe wall thickness, concrete strength, properties of the timber packers and the deections that can be expected at pipe joints during installation. The allowable jacking forces and associated maximum joint deections are calculated in accordance with the Concrete Pipe Association of Australasia (CPAA) publication, Jacking Design Guidelines.
Source: Jacking Design Guidelines, Concrete Pipe Association of Australasia.

As such a minimum Class 4 pipe is usually recommended although in some short length drives a Class 3 may be suitable. The Class 4 pipe to Australian Standard AS/NZS 4058: 2007 has very similar strength requirements to load classes specied for jacking pipes in European and Japanese Standards. AS/NZS 4058: 2007 outlines the technique for determining the permanent vertical loads acting on pipes installed using pipe jacking. The jacking pipe is installed underground into undisturbed natural ground where the soils natural cohesion contributes to arching over the pipe. Where the calculation includes the effects of arching due to soil cohesion extensive soil investigations should be carried out to determine the appropriate design soil properties. The jacking installation results in a recommended bedding factor between two and three that is used to determine the minimum suitable pipe class required due to permanent loads. Ensure that jacking forces are maintained within the specied limits. If circumstances cause a jacking force/ deection combination outside of these limits, hold the jacking operation and contact Humes for assistance. Jacking force and lateral displacement off line and level have to be recorded at regular intervals of jacking distance (not exceeding 200 mm or every 90 seconds). The CPAA publication, Jacking Design Guidelines, is a recommended guide to calculate and dene jacking forces. The guide can be downloaded by visiting; www.cpaa.asn.au/CPAA-Online-Shop.html Jacking design and forces

12

Jacking pipes

factor for jacking pipes, because they must withstand the high jacking forces necessary to overcome the resistance of the cutting face and the external pipe surface. According to the EN 295 standard, the longitudinal compressive strength of the surfaces that transfer the force between pipe sections must be at least 75 N/mm. STEINZEUG-KERAMO guarantees a value of at least 100 N/mm. That is higher than the values stated for other types of current jacking material. It allows very high jacking forces to be used, although this capability is only partially utilised in practice. The glazed outer surface of the pipe strongly reduces friction between the pipe and the surrounding soil.

Humes vitried clay jacking pipes are manufactured by STEINZEUG-KERAMO (STEINZEUG Abwassersysteme GmbH) and inspected in accordance with the European standard for vitried clay pipes, ttings and joints for drains and sewers - EN 295.

Features and benets

Watertightness The joints are tested in accordance with EN 295, which means that they are guaranteed to be watertight at 0.5 bar, including the angular deections and radial loads specied in the standard. They are also tested in accordance with ZPWN 2951 and ATV A142, with guaranteed watertightness at 2.4 bar. Watertightness is also tested at an external pressure of 6 bar, which provides a high level of security against penetration of soil slurries and bentonite.

High abrasion resistance Vitried clay has high abrasion resistance, which is equally true for the glaze and the rest of the wall. Abrasion values encountered in the tests are approximately 0.08 mm, which is much lower than the typical abrasion values of 0.2 mm to 0.5 mm after 100,000 load cycles measured using the Darmstadt test as specied in the EN 295 standard or the maximum value of 0.25 mm in the ZPWN 295 standard. Abrasion does not accelerate even with extended load cycles, such as up to 400,000, in contrast to what is often suggested in data sheets for competitive materials. The depth of abrasion remains limited to 0.3 - 0.8 mm after 400,000 cycles. Compared with the large wall thicknesses of vitried clay jacking pipes, that represents a negligible loss of wall thickness.

Corrosion resistance Vitried clay material is resistant to all types of chemicals over the entire wall thickness. The resistance of the vitried clay material and seals is tested using chemicals, including sulphuric acid at pH 0 and NaOH at pH 14, in conformance with EN 295 and ZPWN 295.

High mechanical strength Vitried clay jacking pipes generally have greater wall thicknesses than corresponding standard vitried clay sewer pipes, that results in high crown pressure ratings and high resistance to ground and trafc loads.
1. ZPWN 295 is an internal manufacturer standard of STEINZEUG-KERAMO.

Jacking pipes

13

Jacking pipes

Vitried clay pipes

Strength in the length direction is the most important

Resistance to high-pressure cleaning

Right: Vitried clay jacking pipe installation

The requirement included in the ZPWN 295 standard is met (resistance with regard to a standardised maintenance cleaning test at 120 bar and a deblocking test at 340 bar). Here again, vitried clay scores considerably better than many other types of material.

Temperature resistance Pipes and seals are tested at up to 70 C. Vitried clay pipes can tolerate even higher temperatures.

Long service life After being properly installed, vitried clay pipe requires very little maintenance. As vitried clay scores very high with respect to all the requirements that must be imposed on sewer pipes, vitried clay pipes have very long service lives. The important properties mentioned above do not degrade over time. This is especially true for jacking pipes, because they are structurally over dimensioned for their subsequent use and optimally bedded in the ground.

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Jacking pipes

The entire range of vitried clay jacking pipes DN200 to DN1200 are tted with a stainless steel coupling which has a high chrome and nickel content and a relatively signicant molybdenum content. This coupling is highly resistant to corrosion in aggressive soils (acids, chlorides and halogens). Two different types of stainless steel couplings are used, Type 1 and Type 2.

The moulded rubber seal is integrated in a milled groove. The packing ring, which transmits the jacking force, is made from particle board and is pretted to the coupling. Pipes are sawn and milled at both ends to yield parallel end faces. For diameters DN600 and above a clamping (prestressing) ring is tted at each spigot end. This ring increases the permissible jacking force and provides additional protection in case of poorly controlled steering motions during jacking or when angular deections occur due to variations in soil conditions. Intermediate re-usable jacking stations can be used with diameters of DN600 and above. This is advisable for long jacking distances and when jacking forces exceeding the specied limits are anticipated. The intermediate jacking stations are coupled to the spigot ends of the pipes and recovered in the receival pit or an intermediate shaft.

DN200 to DN300 with Type 1 stainless steel coupling The moulded elastomer seal is integrated into the ring. The packing ring, which transmits the jacking force is made from elastomer for diameters up to DN300 and forms a unit with the moulded sealing ring. Pipes are sawn at both ends to yield parallel end faces. The spigot ends are milled. The precision ground safe internal working pressure of 2.4 bar. The sealing capabilities of the coupler due to its special design not only guarantees joint integrity, but ensures full protection from the ingress of matter during the jacking process. spigots as for larger dimension jacking pipes permit a

The trenchless mode of construction

Figure 8 Typical vitried clay pipe jacking set up

At the present time two remote steered methods for the construction of underground sewers are in use. These two methods are described below in accordance with ATV

bentonite suspensions are used, special sand Jacking pipes removal equipment is used. The drive for the cutting head and for the steering cylinders are located in the jacking shield. In general this

15

Jacking pipes

Product range

DN400 to DN1200 with Type 2 stainless steel coupling

Figure 9 Joint proles for DN200 to DN300 pipe with Type 1 coupling
Detail 2 2

bk

dz d1 d3 dM dk dzi

l1

sk

Jacking direction

Table 5 Dimensions for DN200 to DN300 pipe with Type 1 coupling (refer Figure 9 above) Max. jacking force* Min. crushing load

Pipe dimensions DN Internal d1

5

Coupling Length l1
1

Pressure transfer ring b dz

1

Average weight

Pipe end d3

Pipe body dM

dk
1

k 0.2

k 1.5

za 0.5

zi 0.5

kN

kN/m

kg/m

mm 200 199 244

+2 -2

276

+0 -6

990 990 1,990 990 1,990

49

+3 -1

267.8

1.5

103

10

241

205

350

80

60

250

250

322

+0 -1

360

+0 -6

48

+3 -0

342.8

1.5

106

10

320

257

810

110

105

300

299

374

+0 -1

406

+0 -10

48

+3 -0

395.8

2.0

106

10

372

309

1,000

120

125

Notes: 1. * Permissible jacking force for automatic recording and control, safety factors 2 and 1.6. 2. Compressive strength = 100 N/mm2. 3. Bending tensile strength = 14 N/mm2. 4. Supplied with wooden pressure transfer ring according to EN 312 P5. 5. The ground spigot ends (d3) are trimmed ca. 2 x 2 mm.

16

Jacking pipes

Figure 10 Joint proles for DN400 to DN1200 pipe with Type 2 coupling
Bevel dm min. 45
e Rubber seal bk Max. dm on this side

dz d1 d3 dM dk dza dzi

Particle board

Prestressing ring6
l1

Sk Jacking direction

Table 6 Dimensions for DN400 to DN1200 pipe with Type 2 coupling (refer Figure 10 above) Pressure transfer ring bk
1

Pipe dimensions Internal d1 DN Pipe end d3

+0 -1

Coupling Length l1
1

Max. jacking force*

Min. crushing load

Average weight

Pipe body dM

e
2

dk
1

sk
0.2

dz
1

dza
1

dzi
1

kN

kN/m

kg/m

mm 400 500 600 700 800 1000 1200 400 498 599 695 792 1,056 1,249
+6 -6 + 7.5 - 7.5 +9 -9

528 632 723 827 921 1,218 1,408

556 661 766 870 970 1,275 1,475

+0 - 12 +0 - 15 +0 - 18

984 1,984 1,984 1,981 1,981 1,981 1,981 1,981

65 65 70 70 70 70 80

536 640 731 837 931 1,230 1,422

3 3 3 4 4 5 6

130 130 143 143 143 143 163

16 16 19 19 19 19 19

518 624 713 816 911

413 513 615 715 823

2,350 3,000 3,100 3,300 3,700 5,700 6,400

160 140 120 140 128 120 114

240 295 350 434 507 855 990

+ 12 - 12 + 12 - 12 + 15 - 15 + 18 - 18

+0 - 24 +0 - 24 +0 - 30 +0 - 36

1,208 1,077 1,397 1,277

Notes: 1. * Permissible jacking force for automatic recording and control, safety factors 2 and 1.6. 2. Compressive strength = 100 N/mm2. 3. Bending tensile strength = 14 N/mm2. 4. Supplied with wooden pressure transfer ring according to EN 312 P5. 5. The ground spigot ends (d3) are trimmed ca. 2 x 2 mm. 6. For diameters DN600 and above a prestressing (clamping) ring is tted at each spigot end.

Jacking pipes

17

Jacking pipes

vitrified clay jacking pipe to a vitrified clay so eted pipe is provided by the use of an bush to equal out the different diameters. Then, w
Connection to standard pipes and access chambers
Right: Milled end of adaptor pipe and socketed end of standard pipe

Three different components are used to connect vitried clay jacking pipes to standard vitried clay pipelines and access chambers.

1. Adaptor pipe for DN200 to DN600 pipes The adaptor pipe is used for connection of vitried clay jacking pipes to open trench vitried clay pipes normal/ high strength class or access chambers. They consist of 1.0 m long jacking pipes with a coupling on one end and the other end milled to the external diameter of the pipe to which the adaptor is to be connected.

Figure 11 Adaptor pipe for DN200 to DN600 pipes

bk e = 180 mm Coupling type 1 or 2

Figure 12 Connection of adaptor pipe to access chamber

Grinded on a length e = 180 mm BKK ring P ring

dz dk d1 d3 dM d3 of the jacking pipe d3 of the standard vc pipe (normal or high strength)

dM

1,000 mm

1,000 mm Inspection chamber with vitried clay invert

Table 7 Dimensions for adaptor pipe for DN200 to DN600 pipes (refer Figure 11 above) Pipe dimensions Internal d1 Pipe end (normal strength) d3
+0 -1

Pipe end (high strength) d3

+0 -1

Pipe body dM

Length (mm) l1
1

DN

mm 250 300 400 500 600 250 299 400 498 601
+3 -3 +5 -5 +6 -6

Average weight (kg/piece) 105 125 240 295 305

299 355 486 581 687

318 376 492 609 721

360 406 556 661 766

+0 -6 +0 -10 +0 -12

1,000 1,000 1,000 1,000 1,000

+7.5 -7.5 +9 -9

+0 -15 +0 -18

18

Jacking pipes

9931 ot 003

-fid retemaid edistuo ot gnidrocca sepyt hsuB .slaes M htiw enibmoc oT .secneref
2. M-seal and bush ring Another way of achieving the transition from a vitried clay jacking pipe to an open trench vitried clay socketed pipe of different external diameter is by using an M-seal and bush ring. The bush ring is used to equal out the outside diameters of the two pipes. The M-seal is a metal banded exible coupling providing a watertight and reliable connection between the jacking and trench pipes. Jacking pipes
Left: M-seal with bush ring

3. Short length pipes Connection of vitried clay jacking pipes to access chambers can also be achieved using short length, 350 mm to 500 mm pipes. Three different types of short installation methods. Type A One end sawn at and the other with a steel coupling. Type B Both ends are sawn at. Type C One end sawn at and one spigot end.
190 Jacking pipe

12 length pipes are available to suit various applications and

Figure 13 M-seal and bush ring

M-seal

85 Standard vc pipe

An M-seal and bush ring is used to connect these three types together.
Sawn at spigot Bush ring

Figure 14 Short length pipes

bk e

Type A dk d1 dM

Type B d1 dM

Type C d1 d2

l1

l1

l1

Jacking pipes

19

Precast solutions
Top: Precast arches Middle: HumeDeck modular bridge system Bottom: Headwall

Tunnel and shaft Access, pipe jacking and ventilation shafts Segmental shafts One piece shafts Mine portals and reclaim tunnels Precast arches Box culverts Corrugated Metal Pipe (CMP) Trafc and utility tunnels Segmental tunnel linings Steel reinforced concrete pipes jacking Vitried clay pipes jacking Escape tunnels and shafts Precast arches Box culverts Steel reinforced concrete pipes Corrugated Metal Pipe (CMP)

Stormwater Sewage transfer and storage Bridge and platform Walling Potable water supply Irrigation supply Trafc management Cable and power management Rail Livestock management

20

Jacking pipes

Contact information
National sales 1300 361 601 humes.com.au [email protected]

Head Ofce
18 Little Cribb St Milton QLD 4064 Ph: (07) 3364 2800 Fax: (07) 3364 2963

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Gnangara

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National sales 1300 361 601 humes.com.au [email protected]

A Division of Holcim Australia

This brochure supersedes all previous literature on this subject. As the specications and details contained in this publication may change please check with Humes Customer Service for conrmation of current issue. This document is provided for information only. Users are advised to make their own determination as to the suitability of this information for their own specic circumstances. We accept no responsibility for any loss or damage resulting from any person acting on this information. Humes is a registered business name and a registered trademark of Holcim (Australia) Pty Ltd. Plastiline is a registered trademark of Holcim (Australia) Pty Ltd. SteInzeUG KeraMo is a registered trademark of STEINZEUG Abwassersysteme GmbH. Swiftlift is a registered trademark of ITW Construction Products Australia Pty Ltd. June 2012 Holcim (Australia) Pty Ltd ABN 87 099 732 297