Tunnel and Shaft Solutions

Tunnel and shaft solutions Issue 2

Contents 3

3-pin precast arches

19

Applications

3

Applications

19

Product range

3

Features and benefits

19


3

Product range

20

Joint and connection details

4

Arch system components

21

Circle joints

4

Box culverts

22

Cross joints

5

Applications

22

6


22

Caulking grooves and sealing grooves

6

Jacking pipes

23

Grout socket assembly

6

The jacking technique (microtunnelling)

23

Benefits of pipe jacking

24

Segmental tunnel linings

Innovative features

Packings

6

Special rings

6

Technical

24

Tunnel construction methods

6

Safety

24

Segmental and one piece shafts

7

Economic

24

Applications

7

Environmental

24


8

Steel reinforced concrete pipes (SRCP)

25

Cost savings

8

Benefits of reinforced concrete jacking pipes

25

Safer work environment

8

Fixed steel collar pipes

26

Minimal environmental impact

8

Loose steel collar pipes

31

Innovative design

8

Selection of jacking pipes

32

Vitrified clay pipes

35

Product range

8

Construction methods

9


35

9

Product range

37

Connection to standard pipes and access chambers

40

Caisson method Underpin method

10

Combination of the caisson and underpin methods

11

Corrugated Metal Pipe (CMP)

42

12

Applications

42

One piece shafts

12


42

Segmental shafts

14

Backfilling

43

Precast solutions

44

Contact information

45

Typical ring configuration

2

Tunnel and shaft solutions


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

Features and benefits • Cost effective installation.

boring machines and poor ground conditions.

-- Non-ferrous self locking, self-aligning connectors reduce internal bolt recesses. -- Segments are provided with a fast coarse thread

Applications

plastic grout socket assembly at the centroid for lifting and grouting.

• Utility tunnels

-- Segments are designed to be machine handled with

• Traffic tunnels (road and rail)

a rotating arm erector.

• Water pipelines

• Three segment types for curved or straight

• Desalination structures

construction. Curved alignments are easily

• Escape tunnels

accommodated by altering the ring orientation (refer to Figure 6 on page 6). • Single pass finish for permanent structures.

Product range

• The elimination of cruciform joints. • The trapezoidal joint arrangement assists with a good

Humes produces segmental linings measuring

ring build and helps maintain the ring shape prior

2 m to 5.3 m (internal) diameter. Other sizes may be

to grouting.

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)

2.07

2.43

1,010

990

2.44

2.80

1,007

2.85

3.21

2.90

Weight per segment (kg)

Ring weight (tonnes)

Bolts per ring No. x dia. x length (mm)

520

3.10

12 x M16 x 295

993

600

3.60

12 x M16 x 355

1,007.5

992.5

700

4.19

12 x M16 x 365

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.

Humes offer segmental tunnel linings in partnership with Buchan Concrete Solutions Limited (UK).


3


• The system is tolerant of a dirty environment and allows for the initial misalignment of segments to compensate for tapered joints and gaskets.

Circle joints

• Highly durable connection with no corrodible parts. A self-locking plastic connector provides a robust joint fixing for tunnel linings.

• The rigid dowel action of the coupler re-aligns the segment and minimises the stepping of joints. • Self-locking and self-aligning.

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.

• 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.

The system has been developed in conjunction with

• Does not induce bursting forces in the concrete.

major tunnelling contractors and is suitable for use in

• Fully compatible with elastic compression gasket. The

traditional open face shields or with the latest full face

elastic performance of the connection compliments

tunnel boring machines.

the behaviour of the gasket, which means that it can be used with a stiff gasket and copes with varying

The self-locking connector offers many benefits:

joint gap.

• The dowels allow a very fast ring erection sequence. • They are designed to reduce lipping between segments.

Figure 1 – Circle joint detail Movable plastic anchors allow segment to be located when imperfectly aligned Shield ram thrust

High strength dowel giving self alignment and good shear connection

Threaded screw connection which allows a push fit

4



Figure 2 – Circle joint connector interaction Water pressure

Gasket compression Self-locking plastic connector extension

Joint gap

25

30o 60o

22.5

30 o

20

ter

12.5

nal

Interna

Stiff EPDM gasket compression characteristic

dia

me

ter ter

15o

l diame

10

Bituminous packing to all longitudinal joints

o

Ex

15

30 o 60

Load (KN)

17.5

Buclock connectors

7.5

Elevation on ringSelf-locking plastic connector extension characteristic 5

2.5 0 0

0.5

1

1.5

2

A resultant joint gap of 1.5 mm @ equilibrium. Gasket sealing performance remains unaffected.

2.5

3

3.5

4

4.5

5

Joint gap (mm)

1 No Plastic grout/Lifting socket Cross joints

Typical circle joint detail 12 no. equally spaced

Figure 3 – Cross joint detail Radiused Curved boltbolt

Sealing Sealinggroove groove

Cross joint connections are made by passing a curved 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

1000 (Nominal)

M16 threaded bolt through a pocket in each segment.

(or Mpa). The segments are cast with bolt hole recesses

Caulking groove groove Caulking

designed to accommodate gel impregnated grommets.

Typical cross joint detail

Inner face of typical segment

All raw materials comply with current Australian standards. Manufacturing is carried out in

Figure 4 – Curved bolts used for cross joints

accordance with the requirements of our quality management system.


5

Innovative features Caulking grooves and sealing grooves All segments are cast with caulking grooves on the

Right: Attaching a grout plug to a grout/ lifting socket

circumferential and longitudinal sides. Sealing grooves for either hydrophilic strip or elastomeric compression gaskets can be incorporated at the time of casting.


Figure 5 – Grout socket assembly

Each segment is fitted with a plastic grout socket

Threaded grout plug

assembly which includes a non-return valve. The socket is used to inject grout to permanently secure the rings.

Sealing washer Non-return valve

Packings

Grout/Lifting socket

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

Figure 6 – Segment orientation for curved and straight alignments

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

Rings in same orientation for curved alignment


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).

Rings rotated at 120° for


6


straightrotated alignment Rings at 120o for straight alignment


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).


7


Innovative design

Precast shafts provide installation contractors with a

• The shaft can be installed accurately due to the

number of significant benefits over traditional shaft

high degree of control over the rate and direction

construction methods; greater installation efficiencies,

of installation.

cost benefits, and a safer work environment. Humes’

• No bracing is required due to its structurally efficient

precast shafts also help to reduce the environmental

circular shape. The shaft gains structural stability from

impact of construction.

the surrounding soil so tie-backs or ring-beams are not required to support the segments. • Suited to a variety of soil conditions.

Cost savings

• Extensive diameter range with full range of ancillary products.

• 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

• 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.

to finish the structure. • There is no requirement for specialist labour and a small team should be capable of managing the entire

Product range

installation process. Humes is proud to announce the expansion of our range of precast concrete shafts; we now offer the following

Safer work environment

sizes in one piece and segmental shafts: • 2.4 m one piece shaft

Humes’ precast shafts enable contractors to provide a

• 3 m one piece shaft

safer environment for their workers:

• 3.6 m one piece shaft

• The majority of work can be carried out above ground

• 4.5 m segmental shaft

(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.

• 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

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).

8


Humes for availability.

Top: Caisson method of shaft installation showing hydraulic jacks (gallows)

There are three techniques available to install a precast concrete segmental shaft. These are the caisson method,

Bottom: Bottom/choker ring with steel cutting edge

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

fluid in the annulus above the ring is retained. The

piece rings).

choker segments are also designed to bolt the steel cutting edge to the shaft and connect the underpin

• Excavation should be slightly larger in diameter than

segment. Refer to combination method on page 11.

the precast concrete shaft The annulus between the shaft and the excavated

• A steel cutting edge underneath the

ground should be filled with suitable fluid (usually

bottom/choker ring

bentonite with additives as required to suit the ground

The steel cutting edge literally cuts through the

conditions) which acts both as a lubricant but also

ground. An additional function is that it acts

supports the ground during installation. • The bottom/choker ring is wider than the standard

as a stiffener. • All caisson units are provided with grout sockets

ring and the same diameter as the excavation

This allows the exterior annulus to be filled with a

The choker ring is designed to provide a seal diameter

cementitious grout at completion of the installation.

between the shaft and excavated ground so that the


9


Construction methods

Underpin method Top: Underpin method of shaft installation Bottom: Segment lifting frame for 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.

10


Right: Combination method of shaft installation

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. The choker/transition rings are wider than the standard caisson rings allowing the connection of underpin rings below this ring as required. 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.

Figure 7 – Combination method details

Caisson rings

Tie rod Choker ring

Underpin rings Double eye bolt


11


Combination of the caisson and underpin methods

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 Detail – Panelled ring with recesses

Vertical tie rod

Cutting edge

12


Special units

Horizontal joints between one piece caisson units are

Special units include the following:

sealed with both a hydrophilic rubber seal near the external surface and a butyl mastic rubber seal near the

• Panelled rings which include recesses, are designed to provide a shear connection between the precast

internal surface. For temporary installations, a single

concrete shaft and an in-situ cast concrete plug,

butyl mastic seal is likely to be sufficient. In addition,

installed to prevent flotation. Either single or multiple

units come complete with a groove on the inside face

panelled rings are particularly effective for wet

which allows caulking of the internal surface. Horizontal joints between one piece caisson rings are connected with vertical tie rods that are mainly provided

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

for temporary loads during installation. These rods are normally made from galvanised steel. For permanent installations, it is recommended that approximately half

Chloride (PVC)) for added corrosion resistance. • Soft eye rings are applied to small diameter (DN600 or less) microtunnelling applications. Rings

of these rods and couplers be replaced with stainless

can be provided with either reduced or no steel

steel so that the hydrophilic seal is confined during the life of the structure.



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.


Left: One piece shaft Right: Cover slab

13

Segmental shafts

Figure 9 – Installing tapered segments to close the ring

Where shaft diameters exceed the size of the one piece

Tapered left segment

ring '3.60 m ID', the segmental shaft system comes

Tapered right segment Ordinary segment

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 Tapered

Mass per ring (tonnes)

Mass per segment (kg)

Ordinary

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.

14


Top: Curved bolt fitting caisson installation

A unique external fixing is used to join the smooth

Bottom: Curved bolt fitting - underpin installation

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


15



• Circle joints Caisson segmental rings are connected using vertical

Figure 11 – Jointing details (caisson segment) Conduit for tie rod

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

Curved bolt hole recess

segmental shafts have been grouted into position the bolts are redundant.

Figure 12 – Tie rod connection used for caisson installations

Tie rods

Hexagonal couplers

Washer

Gel grommets Tie rods

Figure 13 – Double eye bolt used for underpin installations

Top: Tie rod Bottom: Adjusting the double eye bolt - underpin installation

16


Top: Panelled ring

Special rings and/or segments can also be supplied in

Bottom: Segment packing and detail of stacking spacer

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

Figure 14 – Grout socket assembly

segments is not recommended.

Threaded grout plug Sealing washer

Innovative features • Grout socket assembly Non-return valve

Each segment and ring is fitted with a plastic grout socket assembly which includes a non-return valve.

Grout/Lifting socket

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. Detail

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. • Watertightness All 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. Refer to Figures 15 and 16 on the following page.


17


Special units

30

Load-deflection graph Figure 15 – Load deflection graph 60

TUNNEL SEGMENT GASKET TYPE JS1

55 50

35 30

GAP

25 20 15

26

10 5 0

6.5 7.5 6.5

40

10.25

Load (kN/m) Load (kN/m)

45

10 mm offset 0 0

1 1

2 2

33

30 4 4

5 5

6 6

7 7

8 8

8 9

10 10

11 11

12 12

13 13

14 14

15 15

16 16

Deflection (mm) Deflection (mm)

Figure 16 – WatertightnessWater graph tightness graph 12

10/05

Trelleborg Bakker B.V. tel: +31 180 495 555, fax: +31 180 433 080

11 10

Pressure (bar) Pressure (bar)

9 8 7

6 5 4 3 2 1 0

0 0

1 1

22

3 3

44

55

66

77

88

99

10 10

Gap Gap (mm)

10/05

Trelleborg Bakker B.V. tel: +31 180 495 555, fax: +31 180 433 080

6.5

Gap

10 mm offset

26 30

Right: Ethylene Propylene Diene Manomer gasket placement and detail

18


6.5 7.5

10.25

Detail


3-pin precast arches Features and benefits

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

• Designed to meet the mine’s designated design life

ideal for a variety of complex heavy loading criteria and

and can exceed 100 years.

internal envelopes.

• Delivered in segments to suit light cranes. • Require minimal maintenance since:

A wide range of 3-pin arches have been used for reclaim

- the combination of backfill and overfill protects the

tunnels in mining applications. They are designed to suit

arch element

coal and other mineral stockpiles up to 45 metres.

- it has no exposed metal nor bolting system. • Openings for ventilation, escape accesses and intake

The 3-pin arch is a soil-structure interaction system

valves can be easily accommodated.

where the backfill of the specified zone contributes to

• Grades and curved tunnels can be achieved using the

the load carrying capacity of the arch and becomes part

same type arch profile.

of the structure. Its optimised geometry and the unique

• A unique jointing system without any overlapping,

pinned joint allows it to bear and pass heavy load to

staggering, bolting or cast in-situ joints.

the foundation.

• Self supported during installation, does not require scaffolding or support of backfill. • Easy to clean and maintain as conveyor belts can be

Applications

attached to the internal soffit of the arch allowing sufficient clearance for service vehicles to pass beneath.

• Reclaim tunnels

• Fewer units are required for installation as most arch

• Conveyor tunnels

units are 1.8 m to 2.5 m wide.

• Escape tunnels

• Arches can be installed with minimum disruption to

• Underpasses

conveyor operation.


19

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 11,000 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000

Figure 18 – 3D design analysis

20


8,000

7,000

6,000

5,000

4,000

3,000

2,000

1,000

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

0

Top: Arch system with spandrel wall and wing walls

A range of precast concrete products are usually provided

Middle: Spandrel wall

as part of the arch structure along with a selection of retaining wall structures including:

Bottom: Wing walls

• 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.


21


Arch system components

Box culverts Top and bottom: Construction of a box culvert mine portal

Humes manufactures extra large span box culverts with

Opposite page: Jacking pipe

also available.

spans and leg heights up to 6 metres. For additional strength, prestressed units and post-tensioning are

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.

22



Jacking pipes 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


23

Benefits of pipe jacking

Economic • Less affected by weather condition • Less risk of settlement

Technical

• Minimal surface disruption • Inherent strength of lining.

• Minimal reinstatement

• Smooth internal finish giving good flow characteristics.

• Reduced requirement for utilities diversions in urban areas

• No requirement for secondary lining. • Considerably less joints than a segmental tunnel. • Prevention of ground water ingress by use of pipes

Environmental

with sealed flexible joints. • Provision of invert channels in larger pipes to contain the dry weather flow of a sewer in a combined system.

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

Safety

• Typically the trenchless method will reduce the quantities of incoming and outgoing materials,

Pipe jacking is an inherently safer method than open

with a consequent reduction in tipping of spoil and

trench construction or when considering the risks

quarrying of imported stone fill. This in turn leads to

associated with deep, large section, open excavations:

reduced vehicle movements and subsequently less

• Major reduction in man-hours, opportunities for

associated disruption. • Minimal surface disruption and reinstatement.

accidents to occur are less with pipe jacking.

• Trenchless will not harm existing vegetation.

• In busy urban centres, trenchless operation

• Noise, dirt and smell are minimised.

will not interfere with pedestrian and motor traffic movements. • There is significant reduction in the risk of injury as a

Source: An introduction to pipe jacking and microtunelling design – Pipe Jacking Association UK

result of utility strikes and interface with the public. • Less risk of settlement.

Figure 19 – Typical pipe jacking set up

Detail – Intermediate jacking station

Trail pipe

Rubber rings

Jacking direction

Crane to lower pipes into position

Standard pipe Lubrication port

Jacking direction

Launch shaft with hydraulic jacks

24


Intermediate jacking station to assist longer drives

Timber joint packer Lead pipe (steel can)

Jacks

Thrust ring Standard pipe

Working face with jacking shield

Receival shaft

Humes is Australia’s leading manufacturer of SRCP. We have a wide range of diameters, lengths and


Steel reinforced concrete pipes (SRCP)

Durable Humes SRCP has a number of concrete properties that influence long service life. These properties are: • Ultimate compressive strength: Humes SRCP

strengths available. Our SRCP has a proven track record

compressive strength is usually in the range of up

and can be custom designed for applications such as

to 60 MPa and above. The strength of the pipe is

drainage, sewage, water supply and irrigation.

a result of the materials used in the concrete mix, the mix design, manufacturing techniques and the curing process.

A milestone was achieved when Humes' DN2100, fixed steel collar pipes were jacked 1,030 m without

• Low water absorption, below 4%, due to the density

any intermediate shafts on the Northern Pipeline

and impermeability of the concrete used and

Interconnector – Stage 2, SEQ (refer to our case study on

manufacturing process. AS/NZS 4058-2007 specifies

this project for further details).

a maximum allowable absorption of 6% for all concrete pipes. • A low water/cement (W/C) ratio of below 0.35. The

Benefits of reinforced concrete jacking pipes

W/C ratio is considered a trademark for durable concrete pipe, particularly as high compressive strength is related to this criterion.

Optimal strength

• High alkalinity is controlled by cementitious content Humes SRCP are manufactured and factory tested for

maintained by a proper mix design, material properties

quality to AS/NZS 4058:2007 "Precast concrete pipes

as well as the manufacturing and curing process.

(Pressure and Non-pressure)":

• Concrete pipe aggregates, both coarse and fine, meet the requirements of AS 2758. Aggregates are a key

• A concrete pipe is a rigid pipe system that relies

element in producing quality concrete and in turn,

mostly on the strength of the pipe and is only slightly

quality pipe.

dependent on the strength derived from the soil envelope. The inherent strength of concrete pipe can

Source: Concrete Pipe Facts, Concrete Pipe Association of Australasia, www.cpaa.asn.au/concrete-pipe-facts.html

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.


25

Fixed steel collar pipes

Elastomeric seal

A wide robust range is available from DN300 to DN3000

The elastomeric seal is located with the corrugated

inclusive. They are a custom designed reinforced concrete

steel collar in the S type collar band, factory secured

jacking pipe incorporating a single wide jacking face

internally to the steel socket band with adhesive. While,

including timber packers, a secure steel collar cast

in the J type the seal is retained within the accurately

onto the pipe and a flexible watertight joint. All these

formed recess on the pipe spigot.

being essential for longer pipe jacks and unstable ground conditions.

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

Applications

to either internal or external hydraulic pressure.

The fixed steel collar jacking pipes provides high axial

A muck ring is fitted within the J type joint; limiting the

load transfer capacity and a flexible watertight joint. This

ingress of soil into the joint during jacking. The muck ring

is the ideal jacking pipe for all stormwater, sewerage,

will be compressed by the end of the steel collar.

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 fixed steel collars:

deflected joints with external hydrostatic pressures up

the S type which is fitted into pipes up to DN700 and the

to 400 kPa without visible leaks. On this basis, fixed

J type fitted into remaining sizes (mainly from DN800 to

steel collar jacking pipes are rated for 250 kPa external

DN3000). The steel collar bands are fabricated to high

pressure for the joint deflections shown in Figures 22

tolerances to ensure optimum joint performance.

and 23 on page 29. Humes can design pipes for higher external pressure ratings if required.

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 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.

Figure 20 – S type joint profile

26


Figure 21 – J type joint profile


if required by the project designer for isolation of the

Inert thermoplastic linings

joint from the pipeline environment (see Figure 21 on Humes are able to supply the J type steel collar jacking

page 26). The combination of mild steel collars with internal

pipes complete with corrosion protection linings (either

joint gap sealant can provide a cost effective solution in

High Density Polyethylene (HDPE) or Plastiline®- Polyvinyl

certain ground conditions.

Chloride (PVC)) in accordance with Water Services Association of Australia (WSAA) standard specification WSA113. These linings are a proven method of concrete

Intermediate jacking stations

protection against H2S attack in trunk sewers. Humes have standard designs for intermediate jacking stations and these include trail and lead pipes for all Secondary sealing recess

diameters DN1000 to DN2000. The arrangement of these pipes at the intermediate jacking station is shown in

All J type steel collar jacking pipes are supplied with a

Figure 19 on page 24.

recess on the internal pipe ends which allows for locating a flexible sealant, applied internally after installation,

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 type) Deep spigot groove (J type)

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 type)

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.


27

Optimal strength

Jacking design and forces

Humes fixed collar jacking pipes, both with S and J type

The Concrete Pipe Association of Australasia (CPAA)

collar, are designed with steel reinforcement placed for

publication, Jacking Design Guidelines is a recommended

optimal strength, which combined with the strength and

guide to calculate and define jacking forces. The guide

durability of Humes concrete pipes, provides an excellent

can be downloaded by visiting;

jacking pipe. Steel reinforced concrete jacking pipes are

www.cpaa.asn.au/CPAA-Online-Shop.html

capable of withstanding higher jacking loads. Jacking forces and lateral displacement off line and The jacking load capacity of standard pipes for a range of

level have to be recorded at regular intervals of jacking

joint deflections is illustrated in Figures 22 and 23 on the

distance (not exceeding 200 mm or every 90 seconds).

following page. Pipes with higher jacking loads and/or joint deflections can be designed for specific projects.

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



Figure 22 – S type jacking pipes deflection curves 300

Maximum jacking force (tonnes)

250

200

150

100

50

0 0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.90

0.80

1.00

1.10

1.20

1.30

Maximum joint deflection (degrees) DN300

DN350

DN400

DN450

DN500

DN600

DN700

Figure 23 – J type jacking pipes deflection curves J Series Jacking Pipes 2500 2,500 2250 2,250

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

2000 2,000 1750 1,750 1500 1,500

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

00 0.10 0.10

0.20 0.20

DN800

DN900

DN2700

DN3000

0.30 0.30

DN1000

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 deflection (degrees)

DN1100

DN1200

DN1350

DN1500

DN1650

0.900.90

DN1800

1.001.00

DN2100

1.101.10

DN2400

DN800

DN900

DN1000

DN1100

DN1200

DN1350

DN1500

DN1650

DN1800

DN2100

DN2400

DN2500

DN2700

DN3000

1.20 1.20

DN2500


29

Table 5 – Fixed steel collar pipes dimensions, mass, jacking loads and deflections Swiftlift® anchors

T

C Detail

t

A

D

Pw

B

Pt

L

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 Length 'C' (mm)

ID 'D' (mm)

Thickness 't' (mm)

Pipe mass (kg)

Max. jacking load (tonnes)

Collar type

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

30


In-wall joint pipes

Humes offer two types of loose steel collar SRCP jacking

In-wall joint jacking pipes are available from DN1200

pipes, butt joint and in-wall joint. They are available from

to DN3600 (standard range DN1200 to DN2100). In-wall

DN300 to DN3000 (standard range DN300 to DN2100).

joint jacking pipes incorporate a concrete socket formed


Loose steel collar pipes

in the wall of the pipe, a rubber ring located on the pipe The steel collar is not attached to the pipe (cast with)

spigot and timber packers on one or both joint faces

but rather is fitted onto the pipe before installation. The

(see Figure 25).

collars can be supplied by either Humes or the contractor. • Applications In-wall joint jacking pipes are an economical viable alternative for typically short length applications

Butt joint pipes

where a flexible watertight joint is required, however, Butt joint jacking pipes incorporate a single wide jacking

this type of joint can have limitations in jacking

face. External recesses at each end of the pipe allow for a

load transfer. A J type pipe should be specified in

rolled steel collar to be located between adjacent pipes,

these situations.

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 Steel collar

Steel collar


31

Table 6 – Loose steel collar pipe range In-wall joint Nominal diameter

Internal diameter

Butt joint

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

1,026

1,194

1,163

1,359

DN1350

1,324

1,524

DN1500

1,452

1,676

DN1650

1,596

1,842

DN1800

1,756

2,006

DN1050 DN1200

1,200

1,500

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.

Selection of jacking pipes

In addition, jacking pipes may need to prevent ingress of surrounding soil, groundwater, lubricants or grouts and

The most basic requirements for all jacking pipes is

provide a joint capable of withstanding internal pressure

that they must be capable of supporting the excavation

in sewerage or pressure pipeline applications.

(earth and traffic loads), transferring axial load, providing a shear connection between adjacent pipes and joint

Jacking pipes must meet both the needs of the

flexibility that allows for each pipe to follow the path

contractor and asset owner who is usually represented

excavated in front of the shield.

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.

32


Stakeholder

Jacking pipe requirements or application

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

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

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

Asset owners and contractors

Contractors

Fixed steel collar S type

Loose steel collar J type

Butt joint

In-wall joint

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.


33


Table 7 – Selection of jacking pipes

Load class

The higher value is recommended when the annulus between the pipe and ground is grouted. Grouting

Jacking pipes, as opposed to pipes laid in open

of this annulus with a suitable cementitious grout is

excavations, are subjected to both jacking forces,

recommended in most installations as any voids could

external earth loads and life loads (permanent loads)

create a drainage path external to the pipeline which in

and all of these have to be considered when specifying

turn could lead to soil erosion, lowering of ground water

the pipes.

tables and, in aggressive soil conditions, an increased risk of corrosion of pipe materials.

The effect of the jacking force on the pipe barrel is small on account of the high compressive strength of

The axial loading from the pipe jacking is not directly

the concrete. The joint, however, must be considered

included in the selection of the pipe load class. Timber

because the joint cross-section is smaller, as a rule, than

packers are placed between the jacking faces of the

that of the barrel and the jacking force is transferred

concrete pipes to avoid high stresses that could result

eccentrically across the joint.

from direct concrete to concrete contact. The axial load capacity of the concrete pipe is determined based on

The external earth load on the barrel is equal to or

the minimum pipe wall thickness, concrete strength,

smaller than the trench load on a pipe bedded in a

properties of the timber packers and the deflections that

trench of same width as the excavation (i.e. the outside

can be expected at pipe joints during installation.

diameter of the pipe plus a margin for over-excavation). The jacking method of installation, therefore, is very

The allowable jacking forces and associated maximum

efficient from an external load point of view since the

joint deflections are calculated in accordance with

external earth load is smaller than both trench and

the Concrete Pipe Association of Australasia (CPAA)

embankment load on pipes of the same diameter under

publication, Jacking Design Guidelines.

the same height of fill. 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

Jacking design and forces

requirements to load classes specified for jacking pipes in European and Japanese Standards.

The CPAA publication, Jacking Design Guidelines, is a recommended guide to calculate and define jacking

AS/NZS 4058: 2007 outlines the technique for

forces. The guide can be downloaded by visiting;

determining the permanent vertical loads acting on

www.cpaa.asn.au/CPAA-Online-Shop.html

pipes installed using pipe jacking. The jacking pipe is installed underground into undisturbed natural

Jacking force and lateral displacement off line and

ground where the soil’s natural cohesion contributes to

level have to be recorded at regular intervals of jacking

arching over the pipe. Where the calculation includes

distance (not exceeding 200 mm or every 90 seconds).

the effects of arching due to soil cohesion extensive soil investigations should be carried out to determine the

Ensure that jacking forces are maintained within the

appropriate design soil properties.

specified limits. If circumstances cause a jacking force/ deflection combination outside of these limits, hold the

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.

34


jacking operation and contact Humes for assistance.

Strength in the length direction is the most important

Humes vitrified clay jacking pipes are manufactured by

high jacking forces necessary to overcome the resistance

STEINZEUG-KERAMO (STEINZEUG Abwassersysteme

of the cutting face and the external pipe surface.

GmbH) and inspected in accordance with the European

According to the EN 295 standard, the longitudinal

standard for vitrified clay pipes, fittings and joints for

compressive strength of the surfaces that transfer the

drains and sewers - EN 295.

force between pipe sections must be at least 75 N/mm².


Vitrified clay pipes

factor for jacking pipes, because they must withstand the

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

Watertightness

only partially utilised in practice. The glazed outer surface of the pipe strongly reduces friction between the pipe

The joints are tested in accordance with EN 295, which

and the surrounding soil.

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

High abrasion resistance

in accordance with ZPWN 2951 and ATV A142, with guaranteed watertightness at 2.4 bar. Watertightness

Vitrified clay has high abrasion resistance, which

is also tested at an external pressure of 6 bar, which

is equally true for the glaze and the rest of the

provides a high level of security against penetration of

wall. Abrasion values encountered in the tests are

soil slurries and bentonite.

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

Corrosion resistance

as specified in the EN 295 standard or the maximum value of 0.25 mm in the ZPWN 295 standard. Abrasion

Vitrified clay material is resistant to all types of chemicals

does not accelerate even with extended load cycles, such

over the entire wall thickness. The resistance of the

as up to 400,000, in contrast to what is often suggested

vitrified clay material and seals is tested using chemicals,

in data sheets for competitive materials. The depth of

including sulphuric acid at pH 0 and NaOH at pH 14, in

abrasion remains limited to 0.3 - 0.8 mm after 400,000

conformance with EN 295 and ZPWN 295.

cycles. Compared with the large wall thicknesses of vitrified clay jacking pipes, that represents a negligible loss of wall thickness.

High mechanical strength Vitrified clay jacking pipes generally have greater wall

1. ZPWN 295 is an internal manufacturer standard of STEINZEUG-KERAMO.

thicknesses than corresponding standard vitrified clay sewer pipes, that results in high crown pressure ratings and high resistance to ground and traffic loads.


35

Resistance to high-pressure cleaning Right: Vitrified 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, 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.

36


DN400 to DN1200 with Type 2 stainless steel coupling

The entire range of vitrified clay jacking pipes DN200 to

• The moulded rubber seal is integrated in a milled groove.

DN1200 are fitted with a stainless steel coupling which has a high chrome and nickel content and a relatively


Product range

• The packing ring, which transmits the jacking force, is made from particle board and is prefitted to

significant molybdenum content. This coupling is highly

the coupling.

resistant to corrosion in aggressive soils (acids, chlorides

• Pipes are sawn and milled at both ends to yield parallel

and halogens).

end faces. Two different types of stainless steel couplings are used,

• For diameters DN600 and above a clamping (prestressing) ring is fitted at each spigot end. This ring

Type 1 and Type 2.

increases the permissible jacking force and provides additional protection in case of poorly controlled steering motions during jacking or when angular

DN200 to DN300 with Type 1 stainless steel coupling

deflections occur due to variations in soil conditions. • The moulded elastomer seal is integrated into the ring.

• Intermediate re-usable jacking stations can be used with diameters of DN600 and above. This is advisable

• The packing ring, which transmits the jacking force is made from elastomer for diameters up to DN300 and

for long jacking distances and when jacking forces

forms a unit with the moulded sealing ring.

exceeding the specified limits are anticipated. The

• Pipes are sawn at both ends to yield parallel end faces.

intermediate jacking stations are coupled to the spigot

• The spigot ends are milled. The precision ground

ends of the pipes and recovered in the receival pit or an

The trenchless mode of construction intermediate shaft.

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.

Figure 26 – Typical vitrified 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 Tunnel and shaft solutions removal equipment is used. The drive for the cutting head and for the steering cylinders are located in the jacking shield. In general this

37

Figure 27 – Joint profiles for DN200 to DN300 pipe with Type 1 coupling 2

Detail

2

e

bk

dz d1

d3

dM

dk

dzi

Jacking direction

sk

l1

Table 8 – Dimensions for DN200 to DN300 pipe with Type 1 coupling (refer Figure 27 above)

Pipe dimensions DN Internal d1 ±5

Pipe end d3

Pipe body

Pressure transfer ring

Coupling Length

e

dk

l1

dM

s

b

±1

k ± 0.2

k ± 1.5

267.8

1.5

342.8

395.8

dz

d

Max. jacking force*

Min. crushing load

Average weight

kN

kN/m

kg/m

d

±1

za ± 0.5

zi ± 0.5

103

10

241

205

350

80

60

1.5

106

10

320

257

810

110

105

2.0

106

10

372

309

1,000

120

125

±1

mm 200

199

244

+2

250

250

322

+0

300

299

374

+0

-2

-1

-1

276

360

406

+0

990

49

990 1,990

48

990 1,990

48

-6

+0 -6

+0 -10

+3 -1

+3 -0

+3 -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 (d3) are trimmed ca. 2 x 2 mm.

38



Figure 28 – Joint profiles for DN400 to DN1200 pipe with Type 2 coupling e

Bevel dm min. 45°

bk

Rubber seal

Max. dm on this side

dz d1

d3

dM

dk

dza

dzi

Particle board

Sk

Prestressing ring6 l1

Jacking direction

Table 9 – Dimensions for DN400 to DN1200 pipe with Type 2 coupling (refer Figure 28 above)

Pipe dimensions Internal d1

Pipe end d3

DN

+0 -1

Pipe body

Coupling Length l1

dM

Pressure transfer ring

e

dk

sk

bk

dz

dza

dzi

±2

±1

± 0.2

±1

±1

±1

±1

Max. jacking force*

Min. crushing load

Average weight

kN

kN/m

kg/m

±1

mm 400

400

+6 -6

528

556

+0 - 12

984 1,984

65

536

3

130

16

518

413

2,350

160

240

500

498

+ 7.5 - 7.5

632

661

+0 - 15

1,984

65

640

3

130

16

624

513

3,000

140

295

600

599

+9 -9

723

766

+0 - 18

1,981

70

731

3

143

19

713

615

3,100

120

350

700

695

+ 12

827

870

+0

1,981

70

837

4

143

19

816

715

3,300

140

434

800

792

+ 12 - 12

921

970

+0 - 24

1,981

70

931

4

143

19

911

823

3,700

128

507

1000

1,056

+ 15 - 15

1,218

1,275

+0 - 30

1,981

70

1,230

5

143

19

1,208 1,077

5,700

120

855

1200

1,249

+ 18 - 18

1,408

1,475

+0 - 36

1,981

80

1,422

6

163

19

1,397 1,277

6,400

114

990

- 12

- 24

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 fitted at each spigot end.


39

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 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 30 – Connection of adaptor pipe to access chamber

Figure 29 – Adaptor pipe for DN200 to DN600 pipes e = 180 mm

bk

Grinded on a length e = 180 mm

BKK ring

Coupling type 1 or 2

P ring dz dk

d1

d3

dM

d3 of the jacking pipe

dM

d3 of the standard vc pipe (normal or high strength)

1,000 mm

1,000 mm Inspection chamber with vitrified clay invert

Table 10 – Dimensions for adaptor pipe for DN200 to DN600 pipes (refer Figure 29 above) Pipe dimensions Internal

DN

d1

Pipe end (normal strength) d3

Pipe end (high strength)

+0

d3

-1

+0 -1

Pipe body dM

Length (mm) l1 ±1

mm

40

Average weight (kg/piece)

250

250

+3 -3

299

318

360

+0 -6

1,000

105

300

299

+5 -5

355

376

406

+0 -10

1,000

125

400

400

+6 -6

486

492

556

+0 -12

1,000

240

500

498

+7.5

581

609

661

+0

1,000

295

600

601

+9 -9

687

721

766

1,000

305

-7.5


-15 +0 -18

x

x

x

x

9931 ot 003

-fid retemaid edistuo ot gnidrocca sepyt hsuB .slaes M htiw enibmoc oT .secneref 2. M-seal and bush ring

Left: M-seal with 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, Figure 31 – M-seal and bush ring

350 mm to 500 mm pipes. Three different types of short

12applications and length pipes are available to suit various

M-seal

installation methods. Type A – One end sawn flat and the other with a

85

steel coupling.

Standard vc pipe

Jacking pipe

Type B – Both ends are sawn flat. Type C – One end sawn flat and one spigot end.

190

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

Bush ring

Figure 32 – Short length pipes bk

e

Type A

Type B d1

dk

l1

Type C d1

dM

l1

d1

dM

d2

l1


41


x

Corrugated Metal Pipe (CMP) Humes Corrugated Metal Pipe (CMP) is a helically wound,

Top: CMP on-site manufacturing

lock seamed corrugated metal pipe and is available in

Bottom: CMP used in a culvert application

pipe diameters up to 5.1 m, and wall thicknesses of 1.6 mm, 2 mm, 2.5 mm, 3 mm and 3.5 mm. CMP is manufactured from Z600 galvanised grade 250 steel in two state-of-the-art profiles TR and TRS. Both of these profiles have higher load bearing capacity than similar corrugated sinusoidal profiles with TR outperforming 68 x 13 and TRS outperforming both 125 x 25 and 75 x 25. It is designed in accordance with Australian Standards AS 1761-1985 and AS 1762-1984 Helical Locked Seamed Corrugated Steel Pipe.

Applications • Culverts under haul/temporary roads • Mine and conveyor portals • Safe access to mines and construction sites • Escape tunnels • Conduit casing • Ventilation shafts and air flow columns

Features and benefits • Large diameters and long lengths manufactured economically on-site minimising freight cost. • Large diameter pipes eliminate the high installation cost of multi-plate structures. • On-site manufacture accommodates order variations and additions, and frees up haul roads on mine sites. • Humes’ unique profiles optimise load bearing capacity. • Where pipes are to be joined, dedicated coupling bands are supplied providing a secure fit.

Figure 33 – CMP profiles TR profile

• Humes’ design team ensure customer’s requirements are met. • Large diameter culverts can be laid in live condition (running streams). • Installed CMP has high load bearing capacity.

42


TRS profile


Backfilling CMP is a flexible pipe which replies on soil structure interaction to maintain its structural stability. Tables 11 and 12 below list the maximum cover for each of the CMP profiles.

Table 11 – Maximum cover (m) for TR profile Nominal internal diameter (mm)

Table 12 – Maximum cover (m) for TRS profile Nominal internal diameter (mm)

Wall thickness (mm)

Wall thickness (mm)

1.6

2.0

2.5

3.0

300

++

++

x

x

900

x

x

x

x

x

375

++

++

x

x

1,050

x

x

x

x

x

450

++

++

x

x

1,200

x

x

x

x

x

600

++

++

++

x

1,350

x

x

x

x

x

750

40.5

++

++

x

1,500

x

x

x

x

x

900

34.0

47.5

++

x

1,650

x

x

x

x

x

1,050

29.0

40.5

++

x

1,800

x

x

x

x

x

1,200

25.5

35.5

45.0

++

1,950

16.5

21.5

27.5

33.0

38.5

1,350

22.5

31.5

40.0

49.0

2,100

15.5

20.0

25.5

30.5

36.0

1,500

20.5

28.5

36.0

44.5

2,250

14.5

18.5

23.5

28.5

33.5

1,650

18.5

26.0

33.0

40.0

2,400

13.5

17.5

22.0

26.5

31.5

1,800

16.5

23.5

30.0

37.0

2,550

12.5

16.5

20.5

25.0

29.5

1,950

*

20.5

27.0

34.0

2,700

12.0

15.5

19.5

23.5

28.0

2,100

*

18.5

24.0

30.0

2,850

11.0

14.5

18.5

22.5

26.5

2,250

*

16.5

21.5

27.0

3,000

10.0

13.5

17.5

21.5

25.0

2,400

*

*

19.0

24.5

3,300

*

11.5

15.5

18.5

22.0

2,550

*

*

17.0

22.0

3,600

*

10.0

13.5

16.0

19.5

2,700

*

*

*

19.5

3,900

*

*

12.0

14.0

17.0

2,850

*

*

*

17.0

4,200

*

*

8.0

11.0

14.5

3,000

*

*

*

15.5

4,500

*

*

*

9.5

12.5

4,800

*

*

*

*

10.5

5,100

*

*

*

*

9.5

Notes: • Calculations are based on base material steel thickness, ie without galvanising. • For minimum cover requirements please contact Humes for assistance. • Soil density 19 kN/m3. • * Denotes unsuitable due to flexibility factor greater than 0.250 mm/N. • ++ Denotes height of fill greater than 50 m. • x Denotes not practical for manufacture.

1.6

2.0

2.5

3.0

3.5

Notes: • Calculations are based on base material steel thickness, ie without galvanising. • For minimum cover requirements please contact Humes for assistance. • Soil density 19 kN/m3. • * Denotes unsuitable due to flexibility factor greater than 0.250 mm/N. • x Denotes not practical for manufacture.


43

Precast solutions Top: Precast arches

Tunnel and shaft

Middle: HumeDeck® modular bridge system

Access, pipe jacking and ventilation shafts Segmental shafts One piece shafts

Bottom: Headwall

Mine portals and reclaim tunnels Precast arches Box culverts Corrugated Metal Pipe (CMP) 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 Corrugated Metal Pipe (CMP)

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

44


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

Head Office

New South Wales

18 Little Cribb St

Canberra

Milton QLD 4064

Ph: (02) 6285 5309

Ph: (07) 3364 2800

Fax: (02) 6285 5334

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Ph: (07) 3866 7100

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Bundaberg

Lismore

Adelaide

Ph: (07) 4152 2644

Ph: (02) 6621 3684

Ph: (08) 8168 4544

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Newcastle

Ph: (07) 4924 7900

Ph: (02) 4032 6800

Fax: (07) 4924 7901

Fax: (02) 4032 6822

Sunshine Coast

Sydney

Ph: (08) 9302 8000

Ph: (07) 5472 9700

Ph: (02) 9832 5555

Fax: (08) 9309 1625

Fax: (07) 5472 9711

Fax: (02) 9625 5200

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Tamworth

Ph: (08) 9351 6999

Ph: (07) 4694 1420

Ph: (02) 6763 7300

Fax: (08) 9351 6977

Fax: (07) 4634 3874

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Fax: (03) 6335 6330

Western Australia Gnangara

Perth

Northern Territory

Townsville Ph: (07) 4758 6000

Victoria Darwin

Fax: (07) 4758 6001 Echuca

Ph: (08) 8984 1600

Ph: (03) 5480 2371

Fax: (08) 8984 1614

Fax: (03) 5482 3090

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 specifications and details contained in this publication may change please check with Humes Customer Service for confirmation 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 specific 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. © August 2012 Holcim (Australia) Pty Ltd ABN 87 099 732 297

Tunnel and Shaft Solutions

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