Tunnel and shaft solutions brochure - Humes
Transcript of Tunnel and shaft solutions brochure - Humes
Contents
Segmental tunnel linings 3
Applications 3
Product range 3
Features and benefits 3
Joint and connection details 4
Circle joints 4
Cross joints 5
Innovative features 6
Caulking grooves and sealing grooves 6
Grout socket assembly 6
Packings 6
Special rings 6
Tunnel construction methods 6
Segmental and one piece shafts 7
Applications 7
Features and benefits 8
Cost savings 8
Safer work environment 8
Minimal environmental impact 8
Innovative design 8
Product range 8
Construction methods 9
Caisson method 9
Underpin method 10
Combination of the caisson and
underpin methods
11
Typical ring configuration 12
One piece shafts 12
Segmental shafts 14
3-pin precast arches 19
Applications 19
Features and benefits 19
Product range 20
Arch system components 21
Box culverts 22
Applications 22
Features and benefits 22
Jacking pipes 23
The jacking technique (microtunnelling) 23
Benefits of pipe jacking 24
Technical 24
Safety 24
Economic 24
Environmental 24
Steel reinforced concrete pipes (SRCP) 25
Benefits of reinforced concrete jacking pipes 25
Fixed steel collar pipes 26
Loose steel collar pipes 31
Selection of jacking pipes 32
Vitrified clay pipes 35
Features and benefits 35
Product range 37
Connection to standard pipes and
access chambers
40
Precast solutions 42
Contact information 43
Segmental tunnel linings
Humes’ trapezoidal segments use the latest technology
to deliver a smooth bore, single pass tunnel, which can
withstand the increasing demands of modern tunnel
boring machines and poor ground conditions.
Applications
• Utility tunnels
• Traffic tunnels (road and rail)
• Water pipelines
• Desalination structures
• Escape tunnels
Product range
Humes produces segmental linings measuring
2 m to 5.3 m (internal) diameter. Other sizes may be
produced on request (refer to Table 1 below).
Table 1 – Segmental tunnel linings details
Internal
diameter
(m)
External
diameter
(m)
Maximum
segment width
(mm)
Minimum
segment width
(mm)
Weight per
segment
(kg)
Ring
weight
(tonnes)
Bolts per ring
No. x dia. x length
(mm)
2.07 2.43 1,010 990 520 3.10 12 x M16 x 295
2.44 2.80 1,007 993 600 3.60 12 x M16 x 355
2.85 3.21 1,007.5 992.5 700 4.19 12 x M16 x 365
2.90 3.26 1,005 995 710 4.27 12 x M16 x 365
3.00 3.35 1,210.5 1,189.5 856 5.13 12 x M16 x 365
3.35 3.71 1,010 1,000 820 4.89 12 x M16 x 400
3.38 3.84 1,083 1,051 1,200 6.80 12 x M20 x 490
3.84 4.24 1,015 985 1,040 6.20 12 x M20 x 410
5.30 5.80 1,522 1,478 2,090 16.67 12 x M20 x 440
Note:These specifications and details may change, please contact Humes for confirmation.
Features and benefits
• Cost effective installation.
- Non-ferrous self locking, self-aligning connectors
reduce internal bolt recesses.
- Segments are provided with a fast coarse thread
plastic grout socket assembly at the centroid for
lifting and grouting.
- Segments are designed to be machine handled with
a rotating arm erector.
• Three segment types for curved or straight
construction. Curved alignments are easily
accommodated by altering the ring orientation (refer
to Figure 6 on page 6).
• Single pass finish for permanent structures.
• The elimination of cruciform joints.
• The trapezoidal joint arrangement assists with a good
ring build and helps maintain the ring shape prior
to grouting.
Humes offer segmental tunnel linings in partnership with Buchan Concrete Solutions Limited (UK).
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Joint and connection details
Circle joints
A self-locking plastic connector provides a robust joint
fixing for tunnel linings.
The connector is manufactured from a high strength
durable plastic. It combines the advantages of a bolted
connection with the speed, economy and alignment
characteristics of a dowel.
The system has been developed in conjunction with
major tunnelling contractors and is suitable for use in
traditional open face shields or with the latest full face
tunnel boring machines.
The self-locking connector offers many benefits:
• The dowels allow a very fast ring erection sequence.
• They are designed to reduce lipping between segments.
Figure 1 – Circle joint detail
High strength dowel giving self alignment and good shear connection
Movable plastic anchors allow segment to be located when imperfectly aligned
Threaded screw connection which allows a push fit
Shield ram thrust
• The system is tolerant of a dirty environment and
allows for the initial misalignment of segments to
compensate for tapered joints and gaskets.
• Highly durable connection with no corrodible parts.
• The rigid dowel action of the coupler re-aligns the
segment and minimises the stepping of joints.
• Self-locking and self-aligning.
• No circle joint pockets to fill, thus reducing
finishing time.
• Suitable for use with all types of sealing systems,
including Ethylene Propylene Diene Monomer (EPDM)
compression gaskets and hydrophilic seals.
• Does not induce bursting forces in the concrete.
• Fully compatible with elastic compression gasket. The
elastic performance of the connection compliments
the behaviour of the gasket, which means that it can
be used with a stiff gasket and copes with varying
joint gap.
4 Tunnel and shaft solutions
Cross joints
Cross joint connections are made by passing a curved
M16 threaded bolt through a pocket in each segment.
The bolts are made for grade 8.8 steel and have a
nominal ultimate tensile strength (UTS) of 800 N/mm2
(or Mpa) and a nominal yield strength of 640 N/mm2
(or Mpa). The segments are cast with bolt hole recesses
designed to accommodate gel impregnated grommets.
All raw materials comply with current Australian
standards. Manufacturing is carried out in
accordance with the requirements of our quality
management system.
Figure 3 – Cross joint detail
Figure 4 – Curved bolts used for cross joints
30o
Internal diameter
External diameter
60o 30 o
30 o
60 o
15o
1000 (Nom
inal)
1 No Plastic grout/Lifting socket
Elevation on ring
Inner face of typical segment Typical cross joint detail
Sealing groove
Caulking groove
Radiused bolt
12 no. equally spaced
Bituminous packing to all longitudinal joints
Typical circle joint detail
Buclock connectors
Sealing groove Curved bolt
Caulking groove
Figure 2 – Circle joint connector interaction
Water pressure
Gasket compression
Stiff EPDM gasket compression characteristic
Load
(KN
)
Joint gap (mm)
00 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
2.5
5
7.5
10
12.5
15
17.5
20
22.5
25Joint gap
Self-locking plastic connector extension
A resultant joint gap of 1.5 mm @ equilibrium. Gasket sealing performance remains unaffected.
Self-locking plastic connector extension characteristic
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Innovative features
Caulking grooves and sealing grooves
All segments are cast with caulking grooves on the
circumferential and longitudinal sides. Sealing grooves
for either hydrophilic strip or elastomeric compression
gaskets can be incorporated at the time of casting.
Grout socket assembly
Each segment is fitted with a plastic grout socket
assembly which includes a non-return valve. The socket is
used to inject grout to permanently secure the rings.
Packings
Bituminous felt packing of 3 mm nominal thickness
should be used on all longitudinal joints and can be
supplied if required. Circumferential packings made from
3 mm bituminous felt or 3 mm or 6 mm timber can also
be supplied if required.
Special rings
The rings currently available have a taper across one
axis. Non standard tapers can be manufactured to the
purchaser’s specific requirements.
Tunnel construction methods
The rings consist of three different segment types.
Segments are supplied to the erector in a predetermined
sequence dependant upon the alignment required.
The ring orientation is altered by erecting segments in a
different order (refer to Figure 6).
Figure 6 – Segment orientation for curved and
straight alignments
Rings in same orientationfor curved alignment
Rings rotated at 120o
for straight alignment
Rings in same orientationfor curved alignment
Rings rotated at 120o
for straight alignment
Rings in same orientation for curved alignment
Rings rotated at 120° for straight alignment
Figure 5 – Grout socket assembly
Grout/Lifting socket
Non-return valve
Sealing washer
Threaded grout plug
Right: Attaching a grout plug to a grout/lifting socket
6 Tunnel and shaft solutions
Segmental and one piece shafts
Applications
Humes’ precast concrete shafts are an economical
and safe solution for permanent and temporary
underground structures. They are ideal for a variety of
applications including:
• ventilation shafts
• escape shafts
• launch and receival shafts for pipe jacking applications
• storage overflow and pump stations (sewerage)
• water harvesting and reuse.
The shaft system suits a variety of soil conditions, and
provides a soil and watertight solution.
Humes offer segmental shafts in partnership with Buchan Concrete Solutions Limited (UK).
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Features and benefits
Precast shafts provide installation contractors with a
number of significant benefits over traditional shaft
construction methods; greater installation efficiencies,
cost benefits, and a safer work environment. Humes’
precast shafts also help to reduce the environmental
impact of construction.
Cost savings
• Installation time is significantly reduced as excavation
and ring placement can be on a continuous cycle.
• The precast concrete segments provide a one-pass
finished shaft, so no further concrete work is required
to finish the structure.
• There is no requirement for specialist labour and a
small team should be capable of managing the entire
installation process.
Safer work environment
Humes’ precast shafts enable contractors to provide a
safer environment for their workers:
• The majority of work can be carried out above ground
(caisson method).
• Overhead services hazards are minimised as no large
cranes are required.
• The system has a built-in safety barrier created by the
installation of the top ring.
Minimal environmental impact
An efficient design means shafts have minimal impact
on project sites and the surrounding environment:
• Noise and ground vibration are virtually eliminated as
no hammering is required.
• The excavation and site storage areas are minimal, as
the precast units are relatively compact at less than
2.5 m wide.
• Shaft installation does not require the use of water or
wet concrete (except for the base and collar).
Innovative design
• The shaft can be installed accurately due to the
high degree of control over the rate and direction
of installation.
• No bracing is required due to its structurally efficient
circular shape. The shaft gains structural stability from
the surrounding soil so tie-backs or ring-beams are not
required to support the segments.
• Suited to a variety of soil conditions.
• Extensive diameter range with full range of
ancillary products.
• A soil and watertight solution.
• A unique external fixing is used to join the segments,
eliminating the need for specialist trades, like welders,
on site.
Product range
Humes is proud to announce the expansion of our range
of precast concrete shafts; we now offer the following
sizes in one piece and segmental shafts:
• 2.4 m one piece shaft
• 3 m one piece shaft
• 3.6 m one piece shaft
• 4.5 m segmental shaft
• 6 m segmental shaft
• 7.5 m segmental shaft
• 9 m segmental shaft
• 10.5 m segmental shaft
• 12.5 m segmental shaft
• 15 m segmental shaft
• Sizes up to 25 m are also available, please contact
Humes for availability.
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Construction methods
There are three techniques available to install a precast
concrete segmental shaft. These are the caisson method,
underpin method and the last method is a combination
of the two. The design of caisson and underpin shafts
requires specialist skills and should be executed by a
designer experienced with these construction methods.
Caisson method
The caisson method is generally used in softer soils with
or without the presence of ground water. Caisson are
either installed as a ‘wet caisson’ where the water level
inside the caisson is slightly higher than the external
ground water level, or as a ‘dry caisson’ where the inside
of the caisson is open to the atmosphere. In the caisson
method, the precast concrete elements are erected at
the surface and are then lowered into the ground whilst
excavation progresses.
There are a number of common features unique
to Humes' caisson shaft systems which facilitate
installation. These are:
• In-situ cast concrete collars
These collars act as a guide ring to keep the caisson
shaft vertical and, in larger diameter shafts, resist the
force from the hydraulic jacks.
• Hydraulic jacks (gallows)
These are installed to both steer the shaft and to add
to the vertical force in addition to the self weight
of the shaft lining (generally not required for one
piece rings).
• Excavation should be slightly larger in diameter than
the precast concrete shaft
The annulus between the shaft and the excavated
ground should be filled with suitable fluid (usually
bentonite with additives as required to suit the ground
conditions) which acts both as a lubricant but also
supports the ground during installation.
• The bottom/choker ring is wider than the standard
ring and the same diameter as the excavation
The choker ring is designed to provide a seal diameter
between the shaft and excavated ground so that the
fluid in the annulus above the ring is retained. The
choker segments are also designed to bolt the steel
cutting edge to the shaft and connect the underpin
segment. Refer to combination method on page 11.
• A steel cutting edge underneath the
bottom/choker ring
The steel cutting edge literally cuts through the
ground. An additional function is that it acts
as a stiffener.
• All caisson units are provided with grout sockets
This allows the exterior annulus to be filled with a
cementitious grout at completion of the installation.
Top: Caisson method of shaft installation showing hydraulic jacks (gallows)
Bottom:Bottom/choker ring with steel cutting edge
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Underpin method
The underpin method can be used in self supported soil
where caisson installation is not possible. In this method,
the precast concrete elements are progressively installed
at the base of the excavation. Segmental rings are built
and the annulus between their outside perimeter and
the excavated ground is immediately grouted.
The recommended installation procedure is as follows:
• Secure the first installed ring by casting a concrete
collar around it prior to excavating underneath
to construct the next ring. Shear connection may
be required.
• Always excavate, install and grout one ring at a time.
This reduces the risk of overloading the upper rings
which could pull down the whole ring build, due to
lack of ground friction.
• Excavation of the next ring below can commence once
the grout reaches it recommended strength.
• The underpin segments are designed to be installed
using a specialised handling/lifting frame. The
segment will be secured into the frame via the plastic
grout socket assembly. If you wish to hire a frame,
contact Humes for assistance.
Top:Underpin method of shaft installation
Bottom: Segment lifting frame for underpin method
10 Tunnel and shaft solutions
Combination of the caisson and underpin methods
A combination of both methods can be used if the
soil condition varies. Installation commences with
the caisson method (using a special choker ring) and
then shifts to the underpin method when the hard
soil ground is reached.
A special choker/transition ring must be used to enable
the shift to the underpin construction method. Once
the caisson rings have been completely grouted and the
steel cutting edge removed. The underpin method can
commence as previously described
With some ground conditions it may be necessary or
cost effective to stop the caisson at a certain depth.
After grouting the exterior annulus, it may be possible
to remove the cutting edge and then continue the shaft
construction using the underpin method.
Left: Combination method of shaft installation
Figure 7 – Combination method details
Caisson rings
Tie rod
Double eye bolt
Underpin rings
Choker ring
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Typical ring configuration
One piece shafts
One piece caisson units are ideally suited for construction
of sewage pump station wet wells, access chambers for
large diameter pipelines and jacking launch or receival
shafts for small diameter microtunnelling. One piece
shafts can be supplied in a range of diameters but
standard sizes are as detailed in Table 2 below.
Table 2 – Standard one piece caisson units*
Nominal
diameter
(DN)
Internal
diameter
(mm)
External
diameter
(mm)
Height of
standard units
(mm)*
Mass of standard
units
(tonnes)
Number of tie
rod couplers
2,400 2,374 2,782 1,000 4.3 6
3,000 3,060 3,460 1,000 5.2 8
3,600 3,600 4,000 1,000 6.0 9
Note:* Dimensions are subject to change. Contact Humes for confirmation.
Figure 8 – One piece shaft used in a pump station application
Cutting edge
Vertical tie rod
Detail – Panelled ring with recesses
12 Tunnel and shaft solutions
Joint and connection details
Horizontal joints between one piece caisson units are
sealed with both a hydrophilic rubber seal near the
external surface and a butyl mastic rubber seal near the
internal surface. For temporary installations, a single
butyl mastic seal is likely to be sufficient. In addition,
units come complete with a groove on the inside face
which allows caulking of the internal surface.
Horizontal joints between one piece caisson rings are
connected with vertical tie rods that are mainly provided
for temporary loads during installation. These rods are
normally made from galvanised steel. For permanent
installations, it is recommended that approximately half
of these rods and couplers be replaced with stainless
steel so that the hydrophilic seal is confined during the
life of the structure. Left:One piece shaft
Right: Cover slab
Special units
Special units include the following:
• Panelled rings which include recesses, are designed
to provide a shear connection between the precast
concrete shaft and an in-situ cast concrete plug,
installed to prevent flotation. Either single or multiple
panelled rings are particularly effective for wet
caissons where the connection plug will be cast prior
to de-watering.
• Rings with corrosion protection linings (either High
Density Polyethylene (HDPE) or Plastiline® - Polyvinyl
Chloride (PVC)) for added corrosion resistance.
• Soft eye rings are applied to small diameter
(DN600 or less) microtunnelling applications. Rings
can be provided with either reduced or no steel
reinforcement at pipe penetrations.
• Cover slabs incorporating openings and/or lids as
required. The joint and connection details for the
standard rings are included with these cover slabs.
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Segmental shafts
Where shaft diameters exceed the size of the one piece
ring '3.60 m ID', the segmental shaft system comes
into its own so that shafts of almost any diameter
can be constructed.
A ring consists of a series of ordinary segments which
have four edges that are perpendicular to each other
and two tapered segments (left and right) which have
one tapered end which allows for closing of the ring
by simply lowering the last (tapered right) segment
into position.
Number of segments per ring varies depending on the
shaft diameter (refer to Table 3 below).
Table 3 – Standard segmental shaft details
Internal
diameter
(m)
External
diameter
(m)
Height
(m)
Segments per ring
Mass per ring
(tonnes)
Mass per
segment
(kg)Ordinary Tapered
4.50 4.90 1.00 5 2 7.36 1,050
6.00 6.45 1.00 7 2 10.78 1,200
7.50 7.95 1.00 8 2 13.37 1,340
9.00 9.50 1.00 12 2 17.80 1,270
10.50 11.00 1.00 12 2 25.40 1,820
12.50 13.15 1.00 14 2 32.80 2,050
15.00 15.75 1.00 16 2 44.50 2,500
Note:Diameters up to 25 m are also available, contact Humes for availability.
Tapered left segment
Tapered right segment
Ordinary segment
Figure 9 – Installing tapered segments to close the ring
14 Tunnel and shaft solutions
Joint and connection details
A unique external fixing is used to join the smooth
segmental shaft. The strong connection bolts together
the segments to form a ring. Subsequently, the rings
come together to form a shaft. The system retains
all the benefits of strength, flexibility and speed of
erection whilst providing the client with a safer shaft
construction system.
• Cross joints
Segments are connected across this joint using curved
bolts (refer to Figure 10 below) which are installed
from the outside for caisson installation and from the
inside for underpin installation (see photos).
Figure 10 – Curved bolts used for cross joints
Top:Curved bolt fitting - caisson installation
Bottom:Curved bolt fitting - underpin installation
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• Circle joints
Caisson segmental rings are connected using vertical
tie rods that extend through the full length of the
segments (refer to Figure 11 and 12).
Underpin segmental rings are connected using a
double eye bolt arrangement that allows the joint
to be tightened from inside the shaft (refer to
Figure 13 below).
All bolts used with segmental shaft construction are
made from galvanised steel and are only necessary
to support the shaft during the installation. Once
segmental shafts have been grouted into position the
bolts are redundant.
Figure 12 – Tie rod connection used for caisson
installations
Figure 13 – Double eye bolt used for underpin
installations
Top:Tie rod
Bottom:Adjusting the double eye bolt - underpin installation
Figure 11 – Jointing details (caisson segment)
Tie rods
Tie rods
Hexagonal couplers
Gel grommets
Washer
Conduit for tie rod
Grout socket assembly
Curved bolt hole recess
16 Tunnel and shaft solutions
Top: Panelled ring
Bottom:Segment packing
Figure 14 – Grout socket assembly
Grout/Lifting socket
Non-return valve
Sealing washer
Threaded grout plug
Special units
Special rings and/or segments can also be supplied in
addition to the standard segmental shaft caisson rings:
• Panelled rings
Recesses can be included in both standard rings and
choker rings as required. As with the one piece caisson
rings these are intended to provide a shear connection
between an in-situ cast plug or base slab and the
segmental shaft. It is recommended that complete
panelled ring(s) are installed.
• Soft eye rings
Standard segments are reinforced with steel reinforcing
bars. It is possible to provide rings with some segments
manufactured using fibre reinforcement located at
pipes penetrations for microtunnelling applications. For
the caisson method, a complete ring of fibre reinforced
segments is not recommended.
Innovative features
• Grout socket assembly
Each segment and ring is fitted with a plastic grout
socket assembly which includes a non-return valve.
The assembly is used to introduce bentonite slurry
between the caisson ring and the soil, to lubricate and
reduce friction force while jacking rings into the ground.
The same socket is used to inject grout to permanently
secure the rings. For underpin installations the socket
is also used to secure the segment into the underpin
lifting frame (refer to page 10).
• Packing
Bituminous felt packing of 3 mm nominal thickness is
used on all longitudinal joints. The packing is designed
to prevent direct contact between concrete surfaces
as a result from compressed forces imposed by the
surrounding soil.
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Top and middle:Watertightness testing
Bottom:EPDM gasket placement and detail
Detail
Gap
10.2
5
10 mm offset
6.5
26
30
6.5
7.5
Watertightness
All Humes shaft segments are supplied with Ethylene
Propylene Diene Manomer (EPDM) gaskets fitted
into purpose designed grooves cast around the full
circumference of each segment. In addition, each
segment is cast with caulking grooves on the internal
circumferential and longitudinal sides to meet the specific
requirements of the sealing system.
Humes conducted experiments to determine the
watertightness of our segmental shafts to water ifiltration.
The experiments concluded that the EPDM gasket seals
were successful up to 350 kPa (the testing apparatus
pressure limit). This demonstrated that the seals are
capable of withstanding the effects of pore water pressure
to a depth in excess of 12m depending on soil conditions.
This is in standing with laboratory testing which indicates
the seals are capable of withstanding pressures in excess
of 600 kPa.
In the event that assembly tolerances can’t be achieved
during construction, there is a rectification solution that
has been researched and successfully implemented. This
method involves removing the concrete in the location
of the gap using a masonry drill and injecting a mastic
sealant such as SikaFlex 11-FC into the area.
18 Tunnel and shaft solutions
Humes' precast arch system is a high performance and
cost effective tunnel solution. A large range of custom
designed 3-pin arches have been developed which are
ideal for a variety of complex heavy loading criteria and
internal envelopes.
A wide range of 3-pin arches have been used for reclaim
tunnels in mining applications. They are designed to suit
coal and other mineral stockpiles up to 45 metres.
The 3-pin arch is a soil-structure interaction system
where the backfill of the specified zone contributes to
the load carrying capacity of the arch and becomes part
of the structure. Its optimised geometry and the unique
pinned joint allows it to bear and pass heavy load to
the foundation.
Applications
• Reclaim tunnels
• Conveyor tunnels
• Escape tunnels
• Underpasses
Features and benefits
• Designed to meet the mine’s designated design life
and can exceed 100 years.
• Delivered in segments to suit light cranes.
• Require minimal maintenance since:
- the combination of backfill and overfill protects the
arch element
- it has no exposed metal nor bolting system.
• Openings for ventilation, escape accesses and intake
valves can be easily accommodated.
• Grades and curved tunnels can be achieved using the
same type arch profile.
• A unique jointing system without any overlapping,
staggering, bolting or cast in-situ joints.
• Self supported during installation, does not require
scaffolding or support of backfill.
• Easy to clean and maintain as conveyor belts can be
attached to the internal soffit of the arch allowing
sufficient clearance for service vehicles to pass beneath.
• Fewer units are required for installation as most arch
units are 1.8 m to 2.5 m wide.
• Arches can be installed with minimum disruption to
conveyor operation.
3-pin precast arches
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Product range
Humes 3-pin arches are custom-made to suit specific
project requirements. They are designed to accommodate
the defined envelope, where the function of the tunnel
and loads are applied.
Humes in-house design team can assist in choosing
the most economical 3-pin arch profile (some standard
profiles are shown in Figure 17 below). We will conduct
both linear and non-linear 3D analysis to define
structure suitability, an example of this is shown in
Figure 18 below.
Figure 17 – 3-pin arch profiles
Figure 18 – 3D design analysis
11,000
10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
0
8,00
0
7,00
0
6,00
0
5,00
0
5,00
0
6,00
0
7,00
0
8,00
0
4,00
0
4,00
0
3,00
0
3,00
0
2,00
0
2,00
0
1,00
0
1,00
00
mm
mm
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Arch system components
A range of precast concrete products are usually provided
as part of the arch structure along with a selection of
retaining wall structures including:
• precast concrete feeder chambers to fit intake valves
• spandrel walls which run parallel to the arch, retaining
the backfill at each end of the tunnel. They are
designed to match the arch profile.
• wing walls which are placed at each end of the
spandrel wall to retain the backfill and support the
spandrel walls.
Top: Arch system with spandrel wall and wing walls
Middle: Spandrel wall
Bottom:Wing walls
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Humes manufactures extra large span box culverts with
spans and leg heights up to 6 metres. For additional
strength, prestressed units and post-tensioning are
also available.
A complete precast base and crown unit can be supplied
for fast and easy installation. This will minimise the
need for cast in-situ concrete, especially for remote
mining sites.
Box culverts can also be jacked underneath railways and
roads or slid into a pre-excavated tunnel.
Applications • Portal entries - provide safe ingress and egress for mine
and construction sites
• Conveyer tunnels
• Escape tunnels
• Railways and roads
• Drainage for haul roads
Features and benefits
• Designed to withstand explosion loads and impact
from rock that may fall from a cut face.
• Designed to take heavy mining vehicle loads.
• Blast doors can be fitted into units as required.
• Custom made to suit project specific envelopes.
• Easy to install, no backfilling or jointing of units is
required for structure stability.
• Can be installed to meet site grade condition.
• Conveyor belts are easily attached to the internal
surface of the crown.
Top and bottom: Construction of a box culvert mine portal
Opposite page:Jacking pipe
Box culverts
22 Tunnel and shaft solutions
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 vitrified 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 vitrified 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 vitrified 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
Tunnel and shaft solutions 23
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Benefits of pipe jacking
Technical
• Inherent strength of lining.
• Smooth internal finish giving good flow characteristics.
• No requirement for secondary lining.
• Considerably less joints than a segmental tunnel.
• Prevention of ground water ingress by use of pipes
with sealed flexible joints.
• Provision of invert channels in larger pipes to contain
the dry weather flow of a sewer in a combined system.
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
traffic movements.
• There is significant reduction in the risk of injury as a
result of utility strikes and interface with the public.
• Less risk of settlement.
Crane to lower pipes
into position
Launch shaft with hydraulic jacksIntermediate jacking station
to assist longer drives Receival shaft
Working face with jacking shield
Jacking direction
Trail pipe
Jacking direction
Rubber rings
Timber joint packer
Lead pipe (steel can)
Jacks
Lubrication port
Standard pipe
Standard pipe
Thrust ring
Detail – Intermediate jacking stationFigure 19 – Typical pipe jacking set up
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 benefits to be
gained by the use of pipe jacking techniques when
compared with the traditional open trench approach:
• 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 fill. 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
24 Tunnel and shaft solutions
Steel reinforced concrete pipes (SRCP)
Humes is Australia’s 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,
fixed 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).
Benefits 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 fill heights and
trench depths.
• Concrete pipes are less susceptible to damage
during construction, and maintain their shape by
not deflecting.
• 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
significantly 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.
Durable
Humes SRCP has a number of concrete properties that
influence 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 specifies
a maximum allowable absorption of 6% for all
concrete pipes.
• A low water/cement (W/C) ratio of below 0.35. The
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 fine, 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
Tunnel and shaft solutions 25
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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 flexible watertight joint. All these
being essential for longer pipe jacks and unstable
ground conditions.
Applications
The fixed steel collar jacking pipes provides high axial
load transfer capacity and a flexible watertight joint. This
is the ideal jacking pipe for all stormwater, sewerage,
sleeve pipe and jacked low pressure pipeline applications.
Steel collar types
Humes offer two different types of fixed steel collar:
the S series which is fitted into pipes up to DN700 and
the J series fitted 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.
Figure 20 – S series joint profile Figure 21 – J series joint profile
Elastomeric seal
The elastomeric seal is located with the corrugated steel
collar in the S series, factory secured internally to the
steel socket band with adhesive. While, in the J series 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 deflection
occurs. The joint integrity remains intact when subjected
to either internal or external hydraulic pressure.
A muck ring is fitted within the J series joint; limiting the
ingress of soil into the joint during jacking. The muck ring
will be compressed by the end of the steel collar.
Watertight joint – (External pressure testing)
Humes have undertaken external pressure testing of
deflected joints with external hydrostatic pressures up
to 400 kPa without visible leaks. On this basis, fixed
steel collar jacking pipes are rated for 250 kPa external
pressure for the joint deflections shown in Figures 22
and 23 on page 29. Humes can design pipes for higher
external pressure ratings if required.
Bentonite or grout injection fittings
Pipes can be supplied with or without threaded sockets
and plugs, which are cast into the pipe wall in locations
to meet the project specific requirements for grout and/
or lubrication injection.
26 Tunnel and shaft solutions
Table 4 – Features and benefits
Features Benefit to asset owner Benefit to contractor
Elastomeric seal 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).
Flexibility
Allows joint rotation without damage to the
pipe joint.
Watertight joint
Lubrication fluids are retained in the excavated
annulus without loss of fluid or pressure.
Steel collar fixed to
pipe with in-built
water stop
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.
Secure system
Steel collar will remain watertight and secured
in place during jacking, even in variable
ground conditions.
Efficient jointing
Rapid pipe jointing ensures operational efficiency in
the jacking pit.
Corrugated collar
recess (S series)
Deep spigot groove
(J series)
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.
Restrained seal
Ensures that the seal remains in place during
jointing and jacking with external pressure from
groundwater or lubrication injection.
Single wide
jacking face
Efficient construction
Long drives, lower construction costs and less
disturbance to above-ground activities.
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.
Muck ring
(J series)
Maintain watertight joint
After installation the muck ring protects the rubber
ring and the steel collar to maintain watertightness.
Maintain watertight joint
Prevents ingress of soil into joint during jacking.
Internal joint recess Additional sealing options
The recess is shaped to allow retention of a flexible
sealant if secondary joint sealing is required.
No spalling
Prevents spalling of inside concrete face if the packer
is displaced during jacking.
Inert thermoplastic linings
Humes are able to supply J series 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 specification WSA113. These
linings are a proven method of concrete protection
against H2S attack in trunk sewers.
Secondary sealing recess
All J series steel jacking pipes are supplied with a recess
on the internal pipe ends which allows for locating a
flexible sealant, applied internally after installation,
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.
Intermediate jacking stations
Humes have standard designs for intermediate jacking
stations and these include trail and lead pipes for all
diameters DN1000 to DN2000. The arrangement of these
pipes at the intermediate jacking station is shown in
Figure 19 on page 24.
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Optimal strength
Humes fixed collar jacking pipes 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.
The jacking load capacity of standard pipes for a range of
joint deflections is illustrated in Figures 22 and 23 on the
following page. Pipes with higher jacking loads and/or
joint deflections can be designed for specific projects.
Jacking design and forces
The Concrete Pipe Association of Australasia (CPAA)
publication, Jacking Design Guidelines is a recommended
guide to calculate and define 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
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 specified in Figures 22 and 23 on the following
page. If circumstances cause a jacking force/deflection
combination outside of these limits, hold the jacking
operation and contact Humes for assistance.
28 Tunnel and shaft solutions
Figure 22 – S series jacking pipes deflection curves
Figure 23 – J series jacking pipes deflection curves
Max
imu
m ja
ckin
g fo
rce
(ton
nes
)
300
250
200
150
100
0.90 1.00 1.10 1.20 1.30
50
0
����������������������
�
��
���
���
���
���
���
����� ����� ����� ����� ����� ����� ����� ����� ����� ����� ����� ����� �����
����������������������������������
����
����
����
����
����
��������
��
����� ����� ����� ����� ����� ����� �����
Maximum joint deflection (degrees)
0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80
DN700DN600DN500DN450DN400DN350DN300
DN800 DN900 DN1000
DN1650 DN1800 DN2100 DN2400 DN2500 DN2700 DN3000
DN1100 DN1200 DN1350 DN1500
J Series Jacking Pipes
0
250
500
750
1000
1250
1500
1750
2000
2250
2500
0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20
Maximum Joint De�ection (Degrees)
Max
imum
Jack
ing
Forc
e (T
onne
s)
DN800 DN900 DN1000 DN1100 DN1200 DN1350 DN1500 DN1650 DN1800 DN2100 DN2400 DN2500
DN2700 DN3000
Max
imu
m ja
ckin
g fo
rce
(ton
nes
)
Maximum joint deflection (degrees)
2,500
2,250
2,000
1,750
1,500
1,250
1,000
750
500
250
0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.100
1.20
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Table 5 – Fixed steel collar pipes dimensions, mass, jacking loads and deflections
Nominal
diameter
Internal
diameter
'A'
(mm)
External
diameter
'B'
(mm)
Wall
thickness
'T'
(mm)
Effective
length
'L'
(mm)
Min.
joint
packer
'Pt/Pw'
(mm)
Steel
collar
Pipe mass
(kg)
Max.
jacking
load
(tonnes)
Collar
type
Length
'C'
(mm)
ID
'D'
(mm)
Thickness
't'
(mm)
300 300 430 65 2,400 3/40 50 412 1.5 500 100 S
350 350 480 65 2,400 3/40 50 462 1.5 550 115 S
400 400 540 70 2,400 3/40 50 522 1.5 660 135 S
450 450 606 78 2,400 3/40 50 588 1.5 725 165 S
500 500 672 86 2,400 3/40 50 654 1.5 1,000 225 S
600 600 774 87 2,400 6/60 80 752 2 1,190 240 S
700 700 876 88 2,400 6/60 80 854 2 1,380 280 S
800 800 1,000 100 2,360 12/65 120 989 4 1,800 500 J
900 900 1,110 105 2,360 12/70 120 1,099 4 2,100 500 J
1,000 1,000 1,220 110 2,360 12/75 120 1,209 4 2,400 515 J
1,100 1,100 1,332 116 2,360 12/80 120 1,321 4 2,800 565 J
1,200 1,200 1,450 125 2,360 12/90 120 1,439 4 3,300 650 J
1,350 1,350 1,626 138 2,320 16/90 160 1,611 6 4,000 755 J
1,500 1,500 1,800 150 2,320 16/100 160 1,785 6 4,800 840 J
1,600 1,600 1,940 170 2,985 16/110 160 1,911 8 7,500 1,020 J
1,650 1,650 1,974 162 2,320 16/110 160 1,959 6 5,700 925 J
1,800 1,800 2,150 175 2,320 16/125 160 2,135 6 6,700 1,050 J
2,100 2,100 2,500 200 2,985 16/160 160 2,481 8 12,050 1,440 J
2,400 2,374 2,783 204 2,985 16/175 175 2,759 10 12,950 1,485 J
2,500 2,500 3,000 250 2,985 16/195 175 2,977 10 16,650 2,000 J
2,700 2,636 3,096 230 2,985 16/175 175 3,073 10 16,150 1,900 J
3,000 2,972 3,472 250 2,985 16/195 175 3,449 10 19,700 2,220 J
ADPw
Pt
C
t
L
B
TSwiftlift® anchors
Detail
30 Tunnel and shaft solutions
Loose steel collar 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 fitted onto the pipe before installation. The
collars can be supplied by either Humes or the contractor.
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 24).
• Applications
Butt joint jacking pipes can provide a cost effective
solution for typically short length applications
where only limited flexibility 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 filled with grout after installation.
Refer to Table 7 – Selection of jacking pipes (page 33),
which provides a summary of capabilities for each
of the different types of jacking pipes for different
requirements and applications.
Figure 24 – Butt joint profile Figure 25 – In-wall joint profile
In-wall joint pipes
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 25).
• Applications
In-wall joint jacking pipes are an economical viable
alternative for typically short length applications
where a flexible watertight joint is required, however,
this type of joint can have limitations in jacking
load transfer. A J series pipe should be specified in
these situations.
Steel collar Steel collar
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Selection of jacking pipes
The most basic requirements for all jacking pipes is
that they must be capable of supporting the excavation
(earth and traffic loads), transferring axial load, providing
a shear connection between adjacent pipes and joint
flexibility 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 7 opposite provides a
summary of the capabilities of each of our types of
jacking pipes for different requirements and applications.
Table 6 – Loose steel collar pipe range
Nominal
diameter
In-wall joint Butt joint
Internal
diameter
External
diameter
Internal
diameter
External
diameter
mm
DN300 280 362
DN375 363 445
DN475 438 534
DN525 518 616
DN600 586 698
DN675 653 781
DN750 730 864
DN825 790 946
DN900 875 1029
DN975 951 1,111
DN1050 1,026 1,194
DN1200 1,200 1,500 1,163 1,359
DN1350 1,324 1,524
DN1500 1,452 1,676
DN1650 1,596 1,842
DN1800 1,756 2,006
DN1950 1,920 2,220 1,930 2,198
DN2100 2,088 2,388 2,096 2,388
Notes:1. Alternative internal diameters (and external diameters) may be available to suit project
specific 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.
32 Tunnel and shaft solutions
Table 7 – Selection of jacking pipes
Stakeholder
Jacking pipe
requirements or
application
Fixed steel collar Loose steel collar
S series J series Butt joint In-wall joint
Asset owner Standard size class DN300 – DN700 DN800 – DN3000 DN300 – D2100 DN1200 – DN2100
Extended diameter
range*
DN800 Up to DN3600 DN2250 – DN3000 DN2250 – DN3600
Incorporation of inert
thermoplastic lining
N/A Available DN900 > Available
External grouting Suitable for short
lengths
Ideally suited Not suitable Limited suitability†
Internal pressure test
capability (kPa)‡
90 150§ N/A 90
Application of
internal secondary
sealants
N/A Suitable Not suitable Limited suitability
Sewerage pipelines Limited suitability|| Ideally suited Not suitable Suitable
Stormwater pipelines Ideally suited Ideally suited Limited suitability Suitable
Road and rail culverts Ideally suited Ideally suited Limited suitability Suitable
Sleeve pipe
applications
Ideally suited Ideally suited Limited suitability# Suitable
Asset
owners and
contractors
Length of jacked
pipeline (m)
0 – 50†† < DN1000: 0 – 150
DN1000 – DN3000:
no limit‡‡
0 – 50** 0 – 50
External pressure test
capability§§
90 250 N/A 90
Jacking force transfer Excellent Excellent Good Moderate
Intermediate jacking
stations pipes
N/A Available DN900 –
DN3000
To be provided by
contractor
To be provided by
contractor
Contractors Open face shields Suitable Suitable Suitable Suitable
Closed face pressure
shields
Ideally suited Ideally suited Not suitable Limited suitability
Lubrication along
length of pipeline
N/A Ideally suited Not suitable|||| 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 vitrified 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 flow 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 flexibility 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 filled. The butt joint pipe may not provide an effective sealed joint.
Tunnel and shaft solutions 33
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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
efficient 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 fill.
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 specified 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 soil’s 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.
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 deflections that
can be expected at pipe joints during installation.
The allowable jacking forces and associated maximum
joint deflections 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.
Jacking design and forces
The CPAA publication, Jacking Design Guidelines, is a
recommended guide to calculate and define jacking
forces. The guide can be downloaded by visiting;
www.cpaa.asn.au/CPAA-Online-Shop.html
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).
Ensure that jacking forces are maintained within the
specified limits. If circumstances cause a jacking force/
deflection combination outside of these limits, hold the
jacking operation and contact Humes for assistance.
34 Tunnel and shaft solutions
Vitrified clay pipes
Humes vitrified clay jacking pipes are manufactured by
STEINZEUG-KERAMO (STEINZEUG Abwassersysteme
GmbH) and inspected in accordance with the European
standard for vitrified clay pipes, fittings and joints for
drains and sewers - EN 295.
Features and benefits
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 deflections and radial
loads specified 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.
Corrosion resistance
Vitrified clay material is resistant to all types of chemicals
over the entire wall thickness. The resistance of the
vitrified 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
Vitrified clay jacking pipes generally have greater wall
thicknesses than corresponding standard vitrified clay
sewer pipes, that results in high crown pressure ratings
and high resistance to ground and traffic loads.
1. ZPWN 295 is an internal manufacturer standard of STEINZEUG-KERAMO.
Strength in the length direction is the most important
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/mm².
STEINZEUG-KERAMO guarantees a value of at least
100 N/mm². 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.
High abrasion resistance
Vitrified 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 specified 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
vitrified clay jacking pipes, that represents a negligible
loss of wall thickness.
Tunnel and shaft solutions 35
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Resistance to high-pressure cleaning
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, vitrified clay scores
considerably better than many other types of material.
Temperature resistance
Pipes and seals are tested at up to 70 °C. Vitrified clay
pipes can tolerate even higher temperatures.
Long service life
After being properly installed, vitrified clay pipe requires
very little maintenance. As vitrified clay scores very
high with respect to all the requirements that must be
imposed on sewer pipes, vitrified 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.
Right: Vitrified clay jacking pipe installation
36 Tunnel and shaft solutions
Product range
The entire range of vitrified clay jacking pipes DN200 to
DN1200 are fitted with a stainless steel coupling which
has a high chrome and nickel content and a relatively
significant 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.
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
spigots as for larger dimension jacking pipes permit a
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.
DN400 to DN1200 with Type 2 stainless steel coupling
• Themouldedrubbersealisintegratedina
milled groove.
• Thepackingring,whichtransmitsthejackingforce,
is made from particle board and is prefitted to
the coupling.
• Pipesaresawnandmilledatbothendstoyieldparallel
end faces.
• FordiametersDN600andaboveaclamping
(prestressing) ring is fitted 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
deflections occur due to variations in soil conditions.
• Intermediatere-usablejackingstationscanbeused
with diameters of DN600 and above. This is advisable
for long jacking distances and when jacking forces
exceeding the specified 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.The trenchless mode of construction
12
At the present time two remote steered meth-ods for the construction of underground sew-ers are in use. These two methods aredescribed below in accordance with ATVworking sheet A 125 - microtunnelling:
Shield pipe jacking (Slurry system)Jacking of casing or media pipes is realisedwith simultaneous full cross-section removal ofthe soil from the working face, counter bal-anced by mechanical and hydraulic loads.Surveying is carried out with a laser beam.Changes in direction are executed with the aidof a cutter head able to be swivelled hydrauli-cally. The spoil is continuously removed, usually bymeans of a hydraulic system. The slurry medi-um is recirculated through a pipe systemplaced inside the vitrified clay pipes, which islengthened each time a new pipe is inserted.The pressure required for the slurry medium iscontrolled by a supply and discharge mecha-nism. If water is used as a slurry medium, it isnormally adequate to use settlement basins. If
bentonite suspensions are used, special sandremoval equipment is used. The drive for thecutting head and for the steering cylinders arelocated in the jacking shield. In general thismethod is used for pipes of external diametersup to 1850 mm and manhole to manholelengths of up to 250 m in earth and rock withand without ground water, the particular man-hole to manhole length possible depending onthe nominal size of the pipes.The cutting wheel to be used on the cutterhead is selected on the basis of the composi-tion of earth. Use of the correct tools selectedin accordance with the consistency of the soiland the anticipated size of the stones enablesthe rate of microtunnelling to be optimised.Cutter heads for rock can be used from DN500. The expert reports on the soil, which areessential for microtunnelling, can be preparedin accordance with DIN 18319, VOB part C. Areprint "Opportunities and limits for microtun-nelling taking into account the excavatingtools" can be obtained from STEINZEUG | KERAMO.
Figure 26 – Typical vitrified clay pipe jacking set up
Tunnel and shaft solutions 37
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Figure 27 – Joint profiles for DN200 to DN300 pipe with Type 1 coupling
Table 8 – Dimensions for DN200 to DN300 pipe with Type 1 coupling (refer Figure 27 above)
DN
Pipe
dimensions Coupling
Pressure
transfer ring
Max.
jacking
force*
Min.
crushing
load
Average
weight
Internal
Pipe
end
Pipe
body Length e dk
± 1
sk
± 0.2
bk
± 1.5
dz
± 1
dza
± 0.5
dzi
± 0.5kN kN/m kg/md
1± 5
d3
dM
l1
± 1
mm
200 199 244+ 2
276+ 0
990 49+ 3
267.8 1.5 103 10 241 205 350 80 60- 2 - 6 - 1
250 250 322+ 0
360+ 0 990
1,99048
+ 3342.8 1.5 106 10 320 257 810 110 105
- 1 - 6 - 0
300 299 374+ 0
406+ 0 990
1,99048
+ 3395.8 2.0 106 10 372 309 1,000 120 125
- 1 -10 - 0
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 (d
3) are trimmed ca. 2 x 2 mm.
l1
Jacking directionsk
dz
e
2
2
d1
bk
d3
dM
dk
dzi
Detail
38 Tunnel and shaft solutions
Figure 28 – Joint profiles for DN400 to DN1200 pipe with Type 2 coupling
Table 9 – Dimensions for DN400 to DN1200 pipe with Type 2 coupling (refer Figure 28 above)
DN
Pipe dimensions CouplingPressure transfer
ring
Max. jacking force*
Min. crushing
loadAverage weight
InternalPipe end Pipe body Length e
± 2
dk
± 1
sk
± 0.2
bk
± 1
dz
± 1
dza
± 1
dzi
± 1 kN kN/m kg/md1 d
3
+0d
M
l1
± 1-1
mm
400 400 + 6 528 556 + 0 984 1,984 65 536 3 130 16 518 413 2,350 160 240
- 6 - 12
500 498 + 7.5 632 661 + 0 1,984 65 640 3 130 16 624 513 3,000 140 295- 7.5 - 15
600 599 + 9 723 766 + 0 1,981 70 731 3 143 19 713 615 3,100 120 350- 9 - 18
700 695 + 12 827 870 + 0 1,981 70 837 4 143 19 816 715 3,300 140 434- 12 - 24
800 792 + 12 921 970 + 0 1,981 70 931 4 143 19 911 823 3,700 128 507- 12 - 24
1000 1,056 + 15 1,218 1,275 + 0 1,981 70 1,230 5 143 19 1,208 1,077 5,700 120 855- 15 - 30
1200 1,249 + 18 1,408 1,475 + 0 1,981 80 1,422 6 163 19 1,397 1,277 6,400 114 990- 18 - 36
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 (d
3) are trimmed ca. 2 x 2 mm.
6. For diameters DN600 and above a prestressing (clamping) ring is fitted at each spigot end.
Max. dm
on this side
l1
Jacking direction
Particle board
Rubber seal
dz
Sk
e
d1
bk
d3 d
Md
kd
zad
zi
Bevel dm
min. 45°
Prestressing ring6
Tunnel and shaft solutions 39
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Connection to standard pipes and access chambers
Three different components are used to connect vitrified
clay jacking pipes to standard vitrified clay pipelines and
access chambers.
1. Adaptor pipe for DN200 to DN600 pipes
The adaptor pipe is used for connection of vitrified clay
jacking pipes to open trench vitrified 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 29 – Adaptor pipe for DN200 to DN600 pipes
85
Connections to standard pipes and shafts
Rocker pipe for connection of jacking pipesto standard pipes with two different outsidediametersFor the connection to chambers or v.c. pipesnormal or high strengthVitrified clay adaptors are used for the transi-tion to standard and high load series socketedpipes. The adaptors consist of 1.0 m longjacking pipes with a coupling on one end andthe other end milled to the external diameter ofthe pipe to which the adaptor should be con-nected. With the aid of a P-ring, the transitionto "K" or "S" jointed pipes (in accordance withjointing system C) can be created.A further way of achieving the transition from avitrified clay jacking pipe to a vitrified clay sock-eted pipe is provided by the use of an bush ringto equal out the different diameters. Then, with
the aid of the metal banded flexible coupling (M-seal type 2B), a watertight and reliable connec-tion is created. The external diameters of thecomponents to be connected must be deter-mined precisely prior to ordering the bushes.
Bush types according to outside diameter dif-ferences. To combine with M seals.
Pipe Diameter Nominal Averagelength weight
DN d1 d3 d3 dM l1+0/–1 +0/–1 max. +/–1 kg/pc
(N) (H)
250 +/–3 299 318 360 +0/-6 1000 105
300 +/–5 355 376 406 +0/-10 1000 125
400 +/–6 486 492 556 +0/-12 1000 240
500 +/–7,5 581 609 661 +0/-15 1000 295
600 +/–9 687 721 766 +0/-18 1000 350
Dimensions in mm; technical changes reserved
Coupling type 1 or 2
In the standard and high load series, transitionsto socketed pipes with "K" and "S" joints inaccordance with system C can be achieved withthe aid of the adaptor ring (P-ring).
DN 250 - DN 600 adaptorOptionally with coupling type 1 or to.
Optionally with d3 dimension for standard or high load pipes.
M-seal (type 2B)
Jacking pipe DN 500 covered steel coupling or V4A
Standard v.c. pipe
Cut off milled spigotBush of rubber elastomer; b = 80 mm(thickness must be matched to the dif-ference to be bridged)
21
Outsite diameter(mm)
thickness (mm)4 8 12 16 24 32
160 to 199 x x x x x200 to 299 x x x x x x300 to 1399 x x x x x
DN(mm)
External diameter
dM
Metal banded flexible coupling type 2Bv.c. normal strength
class (N)v.c. high strength
class (H)
150 213 190-215 or 200-225
200 276225-250 with
bush 16 mm thick265-290
300 406335-360 with
bush 24 mm thick385-410
400 556460-490 with
bush 32 mm thick495-525 or 510-540 or
520-550
500 661570-600 with bush
40 mm thick (16 and 24)610-640 or 630-660 or
650-680
600 766 685-715 730-760 or 750-780
700 870 800-830 or 820-850 860-690
800 970 900-930 or 920-950 970-999
Width metal banded flexible coupling type 2B DN 150 and DN 200: 150 mmWidth metal banded flexible coupling type 2B = DN 250: 190 mm
Right: Milled end of adaptor pipe and socketed end of standard pipe
Coupling type 1 or 2
1,000 mm
bk
dk
d1
d3
dM
dz
e = 180 mm
Table 10 – Dimensions for adaptor pipe for DN200 to DN600 pipes (refer Figure 29 above)
DN
Pipe dimensions
Average weight
(kg/piece)
Internal
Pipe end
(normal strength)
Pipe end
(high strength) Pipe body
Length
(mm)
d1 d
3
+0d
3
+0d
M
l1
± 1-1 -1
mm
250 250 +3 299 318 360 +0 1,000 105-3 -6
300 299 +5 355 376 406 +0 1,000 125-5 -10
400 400 +6 486 492 556 +0 1,000 240-6 -12
500 498 +7.5 581 609 661 +0 1,000 295-7.5 -15
600 601 +9 687 721 766 +0 1,000 305-9 -18
Figure 30 – Connection of adaptor pipe to access chamber
Grinded on a length e = 180 mmBKK ring
P ring
Inspection chamber with vitrified clay invert
d3
of the jacking
pipe
d3 of the
standard vc pipe (normal
or high strength)
dM
1,000 mm
40 Tunnel and shaft solutions
2. M-seal and bush ring
Another way of achieving the transition from a vitrified
clay jacking pipe to an open trench vitrified 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 flexible
coupling providing a watertight and reliable connection
between the jacking and trench pipes.
3. Short length pipes
Connection of vitrified clay jacking pipes to access
chambers can also be achieved using short length,
350 mm to 500 mm pipes. Three different types of short
length pipes are available to suit various applications and
installation methods.
Type A – One end sawn flat and the other with a
steel coupling.
Type B – Both ends are sawn flat.
Type C – One end sawn flat and one spigot end.
An M-seal and bush ring is used to connect these three
types together.
85
Connections to standard pipes and shafts
Rocker pipe for connection of jacking pipesto standard pipes with two different outsidediametersFor the connection to chambers or v.c. pipesnormal or high strengthVitrified clay adaptors are used for the transi-tion to standard and high load series socketedpipes. The adaptors consist of 1.0 m longjacking pipes with a coupling on one end andthe other end milled to the external diameter ofthe pipe to which the adaptor should be con-nected. With the aid of a P-ring, the transitionto "K" or "S" jointed pipes (in accordance withjointing system C) can be created.A further way of achieving the transition from avitrified clay jacking pipe to a vitrified clay sock-eted pipe is provided by the use of an bush ringto equal out the different diameters. Then, with
the aid of the metal banded flexible coupling (M-seal type 2B), a watertight and reliable connec-tion is created. The external diameters of thecomponents to be connected must be deter-mined precisely prior to ordering the bushes.
Bush types according to outside diameter dif-ferences. To combine with M seals.
Pipe DiameterNominalAveragelengthweight
DNd1d3d3dMl1+0/–1+0/–1max.+/–1kg/pc
(N)(H)
250+/–3299318360 +0/-61000105
300+/–5355376406 +0/-101000125
400+/–6486492556 +0/-121000240
500+/–7,5581609661 +0/-151000295
600+/–9687721766 +0/-181000350
Dimensions in mm; technical changes reserved
Coupling type 1 or 2
In the standard and high load series,transitionsto socketed pipes with "K" and "S" joints inaccordance with system C can be achieved withthe aid of the adaptor ring (P-ring).
DN 250 - DN 600 adaptorOptionally with coupling type 1 or to.
Optionally with d3 dimension for standard or high load pipes.
M-seal (type 2B)
Jacking pipe DN 500 covered steel coupling or V4A
Standard v.c.pipe
Cut off milled spigotBush of rubber elastomer; b = 80 mm(thickness must be matched to the dif-ference to be bridged)
21
Outsite diameter(mm)
thickness(mm)4812162432
160 to 199xxxxx200 to 299xxxxxx300 to 1399xxxxx
DN(mm)
External diameter
dM
Metal banded flexible coupling type 2Bv.c. normal strength
class (N)v.c. high strength
class (H)
150213190-215 or 200-225
200276225-250 with
bush 16 mm thick265-290
300406335-360 with
bush 24 mm thick385-410
400556460-490 with
bush 32 mm thick495-525 or 510-540 or
520-550
500661570-600 with bush
40 mm thick (16 and 24)610-640 or 630-660 or
650-680
600766685-715730-760 or 750-780
700870800-830 or 820-850860-690
800970900-930 or 920-950970-999
Width metal banded flexible coupling type 2B DN 150 and DN 200: 150 mmWidth metal banded flexible coupling type 2B = DN 250: 190 mm
Figure 31 – M-seal and bush ring
Figure 32 – Short length pipes
Left: M-seal with bush ring
Jacking pipe
Bush ring
Standard vc pipe
85
M-seal
190
Sawn flat spigot
dk
d1
bk
l1
dM
d1
l1
dM
d1 d
2
l1
e
Type A Type B Type C
Tunnel and shaft solutions 41
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Precast solutions
Tunnel and shaft
Access, pipe jacking and ventilation shafts
Segmental shafts
One piece shafts
Mine portals and reclaim tunnels
Precast arches
Box culverts
Traffic and utility tunnels
Segmental tunnel linings
Steel reinforced concrete pipes – jacking
Vitrified clay pipes – jacking
Escape tunnels and shafts
Precast arches
Box culverts
Steel reinforced concrete pipes
Stormwater
Sewage transfer and storage
Bridge and platform
Walling
Potable water supply
Irrigation and rural
Traffic management
Cable and power management
Rail
Livestock management
Top:Precast arches
Middle:HumeDeck® modular bridge system
Bottom:Headwall
42 Tunnel and shaft solutions
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Contact information
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Fax: (03) 6335 6330
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This publication supersedes all previous literature on this subject. As the specifications and details contained in this publication may change please check with Humes Customer Service for confirmation of current issue. This publication provides general information only and is no substitute for professional engineering advice. No representations or warranties are made regarding the accuracy, completeness or relevance of the information provided. Users must make their own determination as to the suitability of this information or any Humes’ product for their specific circumstances. Humes accepts no liability for any loss or damage resulting from any reliance on the information provided in this publication. Humes is a registered business name and registered trademark of Holcim (Australia) Pty Ltd (Holcim). “Strength. Performance. Passion.” is a trademark of Holcim. STEINZEUG KERAMO is a registered trademark of STEINZEUG Abwassersysteme GmbH. Swiftlift is a registered trademark of ITW Construction Products Australia Pty Ltd.
© May 2015 Holcim (Australia) Pty Ltd ABN 87 099 732 297. All rights reserved. This guide or any part of it may not be reproduced without prior written consent of Holcim.
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