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Tunnel and shaft solutions

Issue 3
Contents
Segmental tunnel linings 3 3-pin precast arches 19
Applications 3 Applications 19
Product range 3 Features and benefits 19
Features and benefits 3 Product range 20
Joint and connection details 4 Arch system components 21
Circle joints 4 Box culverts 22
Cross joints 5 Applications 22
Innovative features 6 Features and benefits 22
Caulking grooves and sealing grooves 6 Jacking pipes 23
Grout socket assembly 6 The jacking technique (microtunnelling) 23
Packings 6 Benefits of pipe jacking 24
Special rings 6 Technical 24
Tunnel construction methods 6 Safety 24
Segmental and one piece shafts 7 Economic 24
Applications 7 Environmental 24
Features and benefits 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
Product range 8 Vitrified clay pipes 35
Construction methods 9 Features and benefits 35
Caisson method 9 Product range 37
Underpin method 10 Connection to standard pipes and 40
Combination of the caisson and 11 access chambers
underpin methods Precast solutions 42
Typical ring configuration 12 Contact information 43
One piece shafts 12
Segmental shafts 14
2 Tunnel and shaft solutions
Tunnel and shaft solutions
Segmental tunnel linings
Humes trapezoidal segments use the latest technology Features and benefits
to deliver a smooth bore, single pass tunnel, which can
withstand the increasing demands of modern tunnel 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 External Maximum Minimum Weight per Ring Bolts per ring
diameter diameter segment width segment width segment weight No. x dia. x length
(m) (m) (mm) (mm) (kg) (tonnes) (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.

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

Tunnel and shaft solutions 3


Joint and connection details The system is tolerant of a dirty environment and
allows for the initial misalignment of segments to

Circle joints compensate for tapered joints and gaskets.


Highly durable connection with no corrodible parts.

A self-locking plastic connector provides a robust joint The rigid dowel action of the coupler re-aligns the

fixing for tunnel linings. segment and minimises the stepping of joints.
Self-locking and self-aligning.

The connector is manufactured from a high strength No circle joint pockets to fill, thus reducing

durable plastic. It combines the advantages of a bolted finishing time.

connection with the speed, economy and alignment Suitable for use with all types of sealing systems,

characteristics of a dowel. 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 Tunnel and shaft solutions


Tunnel and shaft solutions
Figure 2 Circle joint connector interaction

Water pressure

Gasket compression

Self-locking
plastic
connector
extension

Joint gap
25

22.5 30o
60o 30 o
20

17.5
Bituminous packing
Ex to all longitudinal joints

30 o
15
ter

60
Load (KN)

o
nal Stiff EPDM gasket compression characteristic
12.5 dia
me
Interna ter
l diame
ter
15o
10

7.5 Buclock connectors


Elevation on ringSelf-locking plastic connector extension characteristic
5

2.5

0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Typical circle joint detail
A resultant joint gap of 1.5 mm @ equilibrium.
Joint gap (mm) 12 no. equally spaced
Gasket sealing performance remains unaffected.

Cross joints
1 No Plastic grout/Lifting socket Figure 3 Cross joint detail

Sealinggroove
Sealing groove Curved boltbolt
Radiused
Cross joint connections are made by passing a curved
M16 threaded bolt through a pocket in each segment.
1000 (Nominal)

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
Caulking groove
Caulking groove
designed to accommodate gel impregnated grommets.
Inner face of typical segment Typical cross joint detail

All raw materials comply with current Australian


Figure 4 Curved bolts used for cross joints
standards. Manufacturing is carried out in
accordance with the requirements of our quality
management system.

Tunnel and shaft solutions 5


Innovative features

Caulking grooves and sealing grooves

Right: All segments are cast with caulking grooves on the


Attaching a grout
plug to a grout/ circumferential and longitudinal sides. Sealing grooves
lifting socket for either hydrophilic strip or elastomeric compression
gaskets can be incorporated at the time of casting.

Figure 5 Grout socket assembly


Grout socket assembly

Each segment is fitted with a plastic grout socket Threaded


grout
assembly which includes a non-return valve. The socket is
plug
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 Figure 6 Segment orientation for curved and
supplied if required. Circumferential packings made from 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
purchasers specific requirements.

Rings in same orientation


Tunnel construction methods for curved alignment
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


Rings in same orientation Rings
straightrotated at 120o
alignment
for curved alignment for straight alignment

6 Tunnel and shaft solutions


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).

Tunnel and shaft solutions 7


Features and benefits 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 A soil and watertight solution.
and ring placement can be on a continuous cycle. A unique external fixing is used to join the segments,
The precast concrete segments provide a one-pass eliminating the need for specialist trades, like welders,
finished shaft, so no further concrete work is required 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). 6 m segmental shaft
Overhead services hazards are minimised as no large 7.5 m segmental shaft
cranes are required. 9 m segmental shaft
The system has a built-in safety barrier created by the 10.5 m segmental shaft
installation of the top ring. 12.5 m segmental shaft
15 m segmental shaft
Sizes up to 25 m are also available, please contact
Minimal environmental impact Humes for availability.

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 Tunnel and shaft solutions


Tunnel and shaft solutions
Construction methods Top:
Caisson method of
shaft installation
showing hydraulic
There are three techniques available to install a precast jacks (gallows)
concrete segmental shaft. These are the caisson method,
Bottom:
underpin method and the last method is a combination Bottom/choker
ring with steel
of the two. The design of caisson and underpin shafts cutting edge
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
Excavation should be slightly larger in diameter than cutting edge to the shaft and connect the underpin
the precast concrete shaft segment. Refer to combination method on page 11.
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.
as a stiffener.
The bottom/choker ring is wider than the standard
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

Tunnel and shaft solutions 9


Underpin method

Top: The underpin method can be used in self supported soil


Underpin method
of shaft installation where caisson installation is not possible. In this method,
the precast concrete elements are progressively installed
Bottom:
Segment lifting at the base of the excavation. Segmental rings are built
frame for underpin
and the annulus between their outside perimeter and
method
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 Tunnel and shaft solutions


Tunnel and shaft solutions
Combination of the caisson and Left:
Combination
underpin methods 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. 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.

Figure 7 Combination method details

Caisson rings

Tie rod

Choker ring

Underpin rings

Double eye bolt

Tunnel and shaft solutions 11


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 Internal External Height of Mass of standard


diameter diameter diameter standard units units Number of tie
(DN) (mm) (mm) (mm)* (tonnes) 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 Tunnel and shaft solutions


Tunnel and shaft solutions
Joint and connection details Special units

Horizontal joints between one piece caisson units are Special units include the following:
sealed with both a hydrophilic rubber seal near the
Panelled rings which include recesses, are designed
external surface and a butyl mastic rubber seal near the
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.
caissons where the connection plug will be cast prior
to de-watering.
Horizontal joints between one piece caisson rings are
Rings with corrosion protection linings (either High
connected with vertical tie rods that are mainly provided
Density Polyethylene (HDPE) or Plastiline - Polyvinyl
for temporary loads during installation. These rods are
Chloride (PVC)) for added corrosion resistance.
normally made from galvanised steel. For permanent
Soft eye rings are applied to small diameter
installations, it is recommended that approximately half
(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
reinforcement at pipe penetrations.
life of the structure. Left:
Cover slabs incorporating openings and/or lids as One piece shaft
required. The joint and connection details for the
Right:
standard rings are included with these cover slabs. Cover slab

Tunnel and shaft solutions 13


Segmental shafts Figure 9 Installing tapered segments to close the ring

Where shaft diameters exceed the size of the one piece Tapered right
Tapered left segment
ring '3.60 m ID', the segmental shaft system comes 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 External Segments per ring Mass per


diameter diameter Height Mass per ring segment
(m) (m) (m) Ordinary Tapered (tonnes) (kg)
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 Tunnel and shaft solutions


Tunnel and shaft solutions
Joint and connection details Top:
Curved bolt fitting -
caisson installation
A unique external fixing is used to join the smooth
Bottom:
segmental shaft. The strong connection bolts together Curved bolt
fitting - underpin
the segments to form a ring. Subsequently, the rings installation
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

Tunnel and shaft solutions 15


Circle joints Figure 11 Jointing details (caisson segment)
Caisson segmental rings are connected using vertical
Conduit for tie rod
tie rods that extend through the full length of the
Grout socket
segments (refer to Figure 11 and 12). assembly

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 Tunnel and shaft solutions


Tunnel and shaft solutions
Special units Top:
Panelled ring

Special rings and/or segments can also be supplied in Bottom:


Segment packing
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.
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.

Tunnel and shaft solutions 17


Watertightness

Top and middle: All Humes shaft segments are supplied with Ethylene
Watertightness
testing
Propylene Diene Manomer (EPDM) gaskets fitted
into purpose designed grooves cast around the full
Bottom:
EPDM gasket circumference of each segment. In addition, each
placement and
segment is cast with caulking grooves on the internal
detail
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 cant 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.

Detail
6.5
10.25

7.5

Gap
6.5

10 mm
offset
26

30

18 Tunnel and shaft solutions


Tunnel and shaft solutions
3-pin precast arches
Humes' precast arch system is a high performance and Features and benefits
cost effective tunnel solution. A large range of custom
designed 3-pin arches have been developed which are Designed to meet the mines 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.

Tunnel and shaft solutions 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
mm

5,000
4,000

3,000
2,000
1,000
0
0
8,000
7,000

6,000
5,000
4,000
3,000
2,000
1,000

1,000

2,000
3,000
4,000
5,000

6,000
7,000
8,000

mm

Figure 18 3D design analysis

20 Tunnel and shaft solutions


Tunnel and shaft solutions
Arch system components Top:
Arch system with
spandrel wall and
wing walls
A range of precast concrete products are usually provided
Middle:
as part of the arch structure along with a selection of
Spandrel wall
retaining wall structures including:
Bottom:
precast concrete feeder chambers to fit intake valves Wing walls

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.

Tunnel and shaft solutions 21


Box culverts
Top and bottom: Humes manufactures extra large span box culverts with
Construction
of a box culvert spans and leg heights up to 6 metres. For additional
mine portal strength, prestressed units and post-tensioning are
Opposite page: also available.
Jacking pipe

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 Tunnel and shaft solutions


Tunnel and shaft solutions
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

Tunnel and shaft solutions 23


Benefits of pipe jacking Economic

Less affected by weather condition


Technical Less risk of settlement
Minimal surface disruption
Inherent strength of lining. Minimal reinstatement
Smooth internal finish giving good flow characteristics. Reduced requirement for utilities diversions in
No requirement for secondary lining. urban areas
Considerably less joints than a segmental tunnel.
Prevention of ground water ingress by use of pipes
with sealed flexible joints. Environmental
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.
accidents to occur are less with pipe jacking. Minimal surface disruption and reinstatement.
In busy urban centres, trenchless operation Trenchless will not harm existing vegetation.
will not interfere with pedestrian and motor Noise, dirt and smell are minimised.
traffic movements.
Source: An introduction to pipe jacking and microtunelling design
There is significant reduction in the risk of injury as a 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

Timber joint packer


Rubber
Trail pipe rings Lead pipe (steel can)

Jacking direction Jacks

Crane to
lower pipes Standard pipe Thrust ring
into position
Lubrication port Standard pipe

Jacking direction Working face with


jacking shield

Intermediate jacking station


Launch shaft with hydraulic jacks to assist longer drives Receival shaft

24 Tunnel and shaft solutions


Tunnel and shaft solutions
Steel reinforced concrete pipes Durable

(SRCP)
Humes SRCP has a number of concrete properties that
influence long service life. These properties are:
Humes is Australias leading manufacturer of SRCP.
We have a wide range of diameters, lengths and 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
A milestone was achieved when Humes' DN2100, curing process.
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
Optimal strength strength is related to this criterion.
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
compensate for site problems not designed for, such as Australasia, www.cpaa.asn.au/concrete-pipe-facts.html

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.

Tunnel and shaft solutions 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 steel
inclusive. They are a custom designed reinforced concrete collar in the S series, factory secured internally to the
jacking pipe incorporating a single wide jacking face steel socket band with adhesive. While, in the J series the
including timber packers, a secure steel collar cast seal is retained within the accurately formed recess on
onto the pipe and a flexible watertight joint. All these 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 series 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 collar: deflected joints with external hydrostatic pressures up
the S series which is fitted into pipes up to DN700 and to 400 kPa without visible leaks. On this basis, fixed
the J series fitted into remaining sizes (mainly from steel collar jacking pipes are rated for 250 kPa external
DN800 to DN3000). The steel collar bands are fabricated pressure for the joint deflections shown in Figures 22
to high 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 series joint profile Figure 21 J series joint profile

26 Tunnel and shaft solutions


Tunnel and shaft solutions
Inert thermoplastic linings if required by the project designer for isolation of the
joint from the pipeline environment (see Figure 21 on
Humes are able to supply J series jacking pipes complete page 26). The combination of mild steel collars with internal
with corrosion protection linings (either High Density joint gap sealant can provide a cost effective solution in
Polyethylene (HDPE) or Plastiline- Polyvinyl Chloride certain ground conditions.
(PVC)) in accordance with Water Services Association of
Australia (WSAA) standard specification WSA113. These
linings are a proven method of concrete protection Intermediate jacking stations
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 series steel jacking pipes are supplied with a recess Figure 19 on page 24.
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 Flexibility
Prevents ingress or egress of water and soil Allows joint rotation without damage to the
surrounding the pipes and allows pressure grouting pipe joint.
of the excavated annulus at the completion of Watertight joint
jacking (if required). Lubrication fluids are retained in the excavated
annulus without loss of fluid or pressure.
Steel collar fixed to Collar material Secure system
pipe with in-built The designer has many options for the grade of Steel collar will remain watertight and secured
water stop steel to suit the intended design life in the installed in place during jacking, even in variable
environment of the pipe. Generally, mild steel is ground conditions.
considered suitable for in-ground conditions and a Efficient jointing
non-aggressive environment. Rapid pipe jointing ensures operational efficiency in
the jacking pit.
Corrugated collar Permanent seal location Restrained seal
recess (S series) The seal remains in place throughout the design Ensures that the seal remains in place during
Deep spigot groove life of the pipeline providing a long-term watertight jointing and jacking with external pressure from
(J series) structure under external groundwater pressures or groundwater or lubrication injection.
ground movement.
Single wide Efficient construction Long drives
jacking face Long drives, lower construction costs and less The wide face on the pipe end enables transfer of
disturbance to above-ground activities. high jacking forces through the centerline of the
pipe wall enabling accurate steering and long drives.
Muck ring Maintain watertight joint Maintain watertight joint
(J series) After installation the muck ring protects the rubber Prevents ingress of soil into joint during jacking.
ring and the steel collar to maintain watertightness.

Internal joint recess Additional sealing options No spalling


The recess is shaped to allow retention of a flexible Prevents spalling of inside concrete face if the packer
sealant if secondary joint sealing is required. is displaced during jacking.

Tunnel and shaft solutions 27


Optimal strength Jacking design and forces

Humes fixed collar jacking pipes are designed with The Concrete Pipe Association of Australasia (CPAA)
steel reinforcement placed for optimal strength, which publication, Jacking Design Guidelines is a recommended
combined with the strength and durability of Humes guide to calculate and define jacking forces. The guide
concrete pipes, provides an excellent jacking pipe. can be downloaded by visiting;
Steel reinforced concrete jacking pipes are capable of www.cpaa.asn.au/CPAA-Online-Shop.html
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 Tunnel and shaft solutions


Tunnel and shaft solutions
Figure 22 S series jacking pipes deflection curves

300

250
Maximum jacking force (tonnes)

200

150

100

50

0
0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30
Maximum joint deflection (degrees)

DN300 DN350 DN400 DN450 DN500 DN600 DN700

Figure 23 J series jacking pipes deflection curves


J Series Jacking Pipes
2500
2,500

2,250
2250

2,000
2000
Maximum jacking force (tonnes)

1,750
Maximum Jacking Force (Tonnes)

1750

1,500
1500

1,250
1250

1,000
1000

750
750

500
500

250
250

00
0.10
0.10 0.20
0.20 0.30
0.30 0.40
0.40 0.50
0.50 0.60
0.60 0.70
0.70 0.80
0.80 0.900.90 1.001.00 1.101.10 1.20 1.20

Maximum Joint Deflection (Degrees)


Maximum joint deflection (degrees)

DN800 DN900 DN1000 DN1100 DN1200 DN1350 DN1500 DN1650 DN1800 DN2100 DN2400 DN2500
DN2700 DN3000 DN800 DN900 DN1000 DN1100 DN1200 DN1350 DN1500
DN1650 DN1800 DN2100 DN2400 DN2500 DN2700 DN3000

Tunnel and shaft solutions 29


Table 5 Fixed steel collar pipes dimensions, mass, jacking loads and deflections

Swiftlift anchors T

C
Detail
t
D A B
Pw

Pt

Steel
Min.
Internal collar
External Wall Effective joint Max.
diameter diameter thickness length packer Length ID Thickness jacking
Nominal 'A' 'B' 'T' 'L' 'Pt/Pw' 'C' 'D' 't' Pipe mass load Collar
diameter (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg) (tonnes) 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 Tunnel and shaft solutions


Tunnel and shaft solutions
Loose steel collar pipes 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
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
Butt joint pipes alternative for typically short length applications
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 series 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

Tunnel and shaft solutions 31


Table 6 Loose steel collar pipe range

In-wall joint Butt joint


Nominal Internal External Internal External
diameter diameter diameter diameter 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.

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 Tunnel and shaft solutions


Tunnel and shaft solutions
Table 7 Selection of jacking pipes

Jacking pipe Fixed steel collar Loose steel collar


requirements or
Stakeholder application S series J series Butt joint In-wall joint
Asset owner Standard size class DN300 DN700 DN800 DN3000 DN300 D2100 DN1200 DN2100

Extended diameter DN800 Up to DN3600 DN2250 DN3000 DN2250 DN3600


range*
Incorporation of inert N/A Available DN900 > Available
thermoplastic lining
External grouting Suitable for short Ideally suited Not suitable Limited suitability
lengths
Internal pressure test 90 150 N/A 90
capability (kPa)
Application of N/A Suitable Not suitable Limited suitability
internal secondary
sealants
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 Ideally suited Ideally suited Limited suitability# Suitable


applications
Asset Length of jacked 0 50 < DN1000: 0 150 0 50** 0 50
owners and pipeline (m) DN1000 DN3000:
contractors no limit
External pressure test 90 250 N/A 90
capability
Jacking force transfer Excellent Excellent Good Moderate

Intermediate jacking N/A Available DN900 To be provided by To be provided by


stations pipes DN3000 contractor contractor
Contractors Open face shields Suitable Suitable Suitable Suitable

Closed face pressure Ideally suited Ideally suited Not suitable Limited suitability
shields
Lubrication along N/A Ideally suited Not suitable|||| Limited suitability
length of pipeline
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


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 soils 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 jacking operation and contact Humes for assistance.

bedding factor between two and three that is used to


determine the minimum suitable pipe class required due
to permanent loads.

34 Tunnel and shaft solutions


Tunnel and shaft solutions
Vitrified clay pipes Strength in the length direction is the most important
factor for jacking pipes, because they must withstand the

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/mm.
STEINZEUG-KERAMO guarantees a value of at least
100 N/mm. That is higher than the values stated for

Features and benefits 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


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

Tunnel and shaft solutions 35


Resistance to high-pressure cleaning

Right: The requirement included in the ZPWN 295 standard


Vitrified clay jacking
pipe installation
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 Tunnel and shaft solutions


Tunnel and shaft solutions
Product range 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
DN1200 are fitted with a stainless steel coupling which milled groove.
has a high chrome and nickel content and a relatively The packing ring, which transmits the jacking force,
significant molybdenum content. This coupling is highly is made from particle board and is prefitted to
resistant to corrosion in aggressive soils (acids, chlorides the coupling.
and halogens). Pipes are sawn and milled at both ends to yield parallel
end faces.
Two different types of stainless steel couplings are used, For diameters DN600 and above a clamping
Type 1 and Type 2. (prestressing) ring is fitted at each spigot end. This ring
increases the permissible jacking force and provides
additional protection in case of poorly controlled
DN200 to DN300 with Type 1 stainless steel coupling steering motions during jacking or when angular
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
The packing ring, which transmits the jacking force is with diameters of DN600 and above. This is advisable
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
spigots as for larger dimension jacking pipes permit a intermediate shaft.
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 meth- bentonite suspensions are used, special sand
Tunnel and shaft solutions 37
ods for the construction of underground sew- removal equipment is used. The drive for the
ers are in use. These two methods are cutting head and for the steering cylinders are
described below in accordance with ATV located in the jacking shield. In general this
Figure 27 Joint profiles for DN200 to DN300 pipe with Type 1 coupling

Detail 2

e bk

dz

d1 d3 dM dk dzi

l1 sk Jacking direction

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

Max. Min.
Pipe Pressure jacking crushing Average
dimensions Coupling transfer ring force* load weight
DN Pipe Pipe
Internal end body Length e dk s b dz d d
k k za zi
1 0.2 1.5 1 0.5 0.5
d1 l1 kN kN/m kg/m
5
d3 dM 1

mm

+2 +0 +3
200 199 244 276 990 49 267.8 1.5 103 10 241 205 350 80 60
-2 -6 -1

+0 +0 990 +3
250 250 322 360 48 342.8 1.5 106 10 320 257 810 110 105
-1 -6 1,990 -0

+0 +0 990 +3
300 299 374 406 48 395.8 2.0 106 10 372 309 1,000 120 125
-1 -10 1,990 -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 Tunnel and shaft solutions


Tunnel and shaft solutions
Figure 28 Joint profiles for DN400 to DN1200 pipe with Type 2 coupling

e Rubber seal bk Max. dm on this side


Bevel dm min. 45

dz

d1 d3 dM dk dza dzi

Particle board

Prestressing ring6 Sk
l1 Jacking direction

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

Max. Min.
Pressure transfer jacking crushing Average
Pipe dimensions Coupling ring force* load weight
Pipe
Internal end Pipe body Length
e dk sk bk dz dza dzi
d1 +0 l1 2 1 0.2 1 1 1 1
kN kN/m kg/m
d3 dM
1
DN -1

mm

+6 +0 984
400 400 528 556 65 536 3 130 16 518 413 2,350 160 240
-6 - 12 1,984
+ 7.5 +0
500 498 - 7.5
632 661 - 15
1,984 65 640 3 130 16 624 513 3,000 140 295

+9 +0
600 599 -9
723 766 - 18
1,981 70 731 3 143 19 713 615 3,100 120 350

+ 12 +0
700 695 827 870 1,981 70 837 4 143 19 816 715 3,300 140 434
- 12 - 24

+ 12 +0
800 792 - 12
921 970 - 24
1,981 70 931 4 143 19 911 823 3,700 128 507

+ 15 +0
1000 1,056 - 15
1,218 1,275 - 30
1,981 70 1,230 5 143 19 1,208 1,077 5,700 120 855

+ 18 +0
1200 1,249 - 18
1,408 1,475 - 36
1,981 80 1,422 6 163 19 1,397 1,277 6,400 114 990

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.

Tunnel and shaft solutions 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: Three different components are used to connect vitrified


Milled end of
adaptor pipe and
clay jacking pipes to standard vitrified clay pipelines and
socketed end of access chambers.
standard pipe

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 Figure 30 Connection of adaptor pipe to access chamber

bk e = 180 mm Grinded on a length e = 180 mm


Coupling type 1 or 2 BKK ring

P ring

dz
dk d1 d3 dM d3 d3 of the
of the standard vc
jacking dM
pipe (normal
pipe 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
Pipe end Pipe end Length
Internal (normal strength) (high strength) Pipe body (mm)

+0 +0 l1
d1 d3 d3 dM
DN -1 -1 1
Average weight
mm (kg/piece)
+3 +0
250 250 -3
299 318 360 -6
1,000 105

+5 +0
300 299 -5
355 376 406 -10
1,000 125

+6 +0
400 400 -6
486 492 556 -12
1,000 240

+7.5 +0
500 498 581 609 661 1,000 295
-7.5 -15

+9 +0
600 601 -9
687 721 766 -18
1,000 305

40 Tunnel and shaft solutions


x x x x x 9931 ot 003
-fid retemaid edistuo ot gnidrocca sepyt hsuB

Tunnel and shaft solutions


.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,
350 mm to 500 mm pipes. Three different types of short Figure 31 M-seal and bush ring
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.
Jacking pipe Standard vc 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 Type C


dk d1 dM d1 dM d1 d2

l1 l1 l1

Tunnel and shaft solutions 41


Precast solutions
Top: Tunnel and shaft
Precast arches

Middle: Access, pipe jacking and ventilation shafts


HumeDeck
modular bridge Segmental shafts
system
One piece shafts
Bottom:
Headwall
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

42 Tunnel and shaft solutions


Contact information
National sales 1300 361 601
humes.com.au
info@humes.com.au

Head Office New South Wales Tasmania

18 Little Cribb St Grafton Launceston


Milton QLD 4064 Ph: (02) 6644 7666 Ph: (03) 6335 6300
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Ph: (07) 4924 7900 Ph: (02) 6763 7300
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Ph: (03) 9360 3888
Fax: (03) 9360 3887 Darwin
Ph: (08) 8984 1600
Fax: (08) 8984 1614
National sales 1300 361 601
humes.com.au
info@humes.com.au

A Division of Holcim Australia

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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