Tunnel and Shaft Solutions

Tunnel and shaft solutions
Issue 2
Contents
Segmental tunnel linings Applications Product range Features and benefits Joint and connection details Circle joints Cross joints Innovative features Caulking grooves and sealing grooves Grout socket assembly Packings Special rings Tunnel construction methods Segmental and one piece shafts Applications Features and benefits Cost savings Safer work environment Minimal environmental impact Innovative design Product range Construction methods Caisson method Underpin method Combination of the caisson and underpin methods Typical ring configuration One piece shafts Segmental shafts 3 3 3 3 4 4 5 6 6 6 6 6 6 7 7 8 8 8 8 8 8 9 9 10 11 12 12 14 3-pin precast arches Applications Features and benefits Product range Arch system components Box culverts Applications Features and benefits Jacking pipes The jacking technique (microtunnelling) Benefits of pipe jacking Technical Safety Economic Environmental Steel reinforced concrete pipes (SRCP) Benefits of reinforced concrete jacking pipes Fixed steel collar pipes Loose steel collar pipes Selection of jacking pipes Vitrified clay pipes Features and benefits Product range Connection to standard pipes and access chambers Corrugated Metal Pipe (CMP) Applications Features and benefits Backfilling Precast solutions Contact information 19 19 19 20 21 22 22 22 23 23 24 24 24 24 24 25 25 26 31 32 35 35 37 40 42 42 42 43 44 45
Segmental tunnel linings

Humes trapezoidal segments use the latest technology to deliver a smooth bore, single pass tunnel, which can withstand the increasing demands of modern tunnel boring machines and poor ground conditions.
Features and benefits

Cost effective installation. - Non-ferrous self locking, self-aligning connectors reduce internal bolt recesses. - Segments are provided with a fast coarse thread plastic grout socket assembly at the centroid for lifting and grouting. - Segments are designed to be machine handled with a rotating arm erector. Three segment types for curved or straight construction. Curved alignments are easily accommodated by altering the ring orientation (refer to Figure 6 on page 6). Single pass finish for permanent structures. The elimination of cruciform joints. The trapezoidal joint arrangement assists with a good ring build and helps maintain the ring shape prior to grouting.
Applications
Utility tunnels Traffic tunnels (road and rail) Water pipelines Desalination structures Escape tunnels
Product range
Humes produces segmental linings measuring 2 m to 5.3 m (internal) diameter. Other sizes may be produced on request (refer to Table 1 below).
Table 1 Segmental tunnel linings details Internal diameter (m) 2.07 2.44 2.85 2.90 3.00 3.35 3.38 3.84 5.30 External diameter (m) 2.43 2.80 3.21 3.26 3.35 3.71 3.84 4.24 5.80 Maximum segment width (mm) 1,010 1,007 1,007.5 1,005 1,210.5 1,010 1,083 1,015 1,522 Minimum segment width (mm) 990 993 992.5 995 1,189.5 1,000 1,051 985 1,478 Weight per segment (kg) 520 600 700 710 856 820 1,200 1,040 2,090 Ring weight (tonnes) 3.10 3.60 4.19 4.27 5.13 4.89 6.80 6.20 16.67 Bolts per ring No. x dia. x length (mm) 12 x M16 x 295 12 x M16 x 355 12 x M16 x 365 12 x M16 x 365 12 x M16 x 365 12 x M16 x 400 12 x M20 x 490 12 x M20 x 410 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).
Joint and connection details

Circle joints
A self-locking plastic connector provides a robust joint fixing for tunnel linings. The connector is manufactured from a high strength durable plastic. It combines the advantages of a bolted connection with the speed, economy and alignment characteristics of a dowel. The system has been developed in conjunction with major tunnelling contractors and is suitable for use in traditional open face shields or with the latest full face tunnel boring machines. The self-locking connector offers many benefits: The dowels allow a very fast ring erection sequence. They are designed to reduce lipping between segments.
The system is tolerant of a dirty environment and allows for the initial misalignment of segments to compensate for tapered joints and gaskets. Highly durable connection with no corrodible parts. The rigid dowel action of the coupler re-aligns the segment and minimises the stepping of joints. Self-locking and self-aligning. No circle joint pockets to fill, thus reducing finishing time. Suitable for use with all types of sealing systems, including Ethylene Propylene Diene Monomer (EPDM) compression gaskets and hydrophilic seals. Does not induce bursting forces in the concrete. Fully compatible with elastic compression gasket. The elastic performance of the connection compliments the behaviour of the gasket, which means that it can be used with a stiff gasket and copes with varying joint gap.
Figure 1 Circle joint detail

Movable plastic anchors allow segment to be located when imperfectly aligned High strength dowel giving self alignment and good shear connection Shield ram thrust
Threaded screw connection which allows a push fit
Figure 2 Circle joint connector interaction

Water pressure
Gasket compression Self-locking plastic connector extension
25 22.5 20 17.5 Load (KN) 15 12.5 10 7.5 5
Joint gap
30o 60o
30 o
Ex
ter
nal
Interna
dia
Stiff EPDM gasket compression characteristic
Bituminous packing to all longitudinal joints
l diame
me
ter ter
Elevation on ring Self-locking plastic connector extension characteristic

2.5 0 0 0.5 1 1.5 2 2.5 Joint gap (mm) 3 3.5 4 4.5 5
Buclock connectors
A resultant joint gap of 1.5 mm @ equilibrium. Gasket sealing performance remains unaffected.
Typical circle joint detail 12 no. equally spaced
1 No Plastic grout/Lifting socket Cross joints
Figure 3 Cross joint detail

Sealing groove Sealing groove Radiused bolt Curved bolt
Cross joint connections are made by passing a curved M16 threaded bolt through a pocket in each segment. The bolts are made for grade 8.8 steel and have a nominal ultimate tensile strength (UTS) of 800 N/mm2 (or Mpa) and a nominal yield strength of 640 N/mm2 (or Mpa). The segments are cast with bolt hole recesses designed to accommodate gel impregnated grommets.
Inner face of typical segment
1000 (Nominal)
Caulking groove Caulkinggroove
Typical cross joint detail
All raw materials comply with current Australian standards. Manufacturing is carried out in accordance with the requirements of our quality management system.
Figure 4 Curved bolts used for cross joints

30 o 60
o
15o
Innovative features
Caulking grooves and sealing grooves
Right: Attaching a grout plug to a grout/ lifting socket
All segments are cast with caulking grooves on the circumferential and longitudinal sides. Sealing grooves for either hydrophilic strip or elastomeric compression gaskets can be incorporated at the time of casting.
Grout socket assembly

Each segment is fitted with a plastic grout socket assembly which includes a non-return valve. The socket is used to inject grout to permanently secure the rings.
Figure 5 Grout socket assembly
Threaded grout plug Sealing washer Non-return valve
Packings
Bituminous felt packing of 3 mm nominal thickness should be used on all longitudinal joints and can be supplied if required. Circumferential packings made from 3 mm bituminous felt or 3 mm or 6 mm timber can also be supplied if required.
Grout/Lifting socket
Figure 6 Segment orientation for curved and straight alignments
Special rings
The rings currently available have a taper across one axis. Non standard tapers can be manufactured to the purchasers specific requirements.
Tunnel construction methods

The rings consist of three different segment types. Segments are supplied to the erector in a predetermined sequence dependant upon the alignment required. The ring orientation is altered by erecting segments in a different order (refer to Figure 6).
Rings in same orientation for curved alignment
straight alignment Rings rotated at 120o for straight alignment
Rings rotated at 120 for
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).

Precast shafts provide installation contractors with a number of significant benefits over traditional shaft construction methods; greater installation efficiencies, cost benefits, and a safer work environment. Humes precast shafts also help to reduce the environmental impact of construction.
Innovative design
The shaft can be installed accurately due to the high degree of control over the rate and direction of installation. No bracing is required due to its structurally efficient circular shape. The shaft gains structural stability from the surrounding soil so tie-backs or ring-beams are not required to support the segments. Suited to a variety of soil conditions.
Cost savings
Installation time is significantly reduced as excavation and ring placement can be on a continuous cycle. The precast concrete segments provide a one-pass finished shaft, so no further concrete work is required to finish the structure. There is no requirement for specialist labour and a small team should be capable of managing the entire installation process.
Extensive diameter range with full range of ancillary products. A soil and watertight solution. A unique external fixing is used to join the segments, eliminating the need for specialist trades, like welders, on site.
Product range
Humes is proud to announce the expansion of our range of precast concrete shafts; we now offer the following
Safer work environment

Humes precast shafts enable contractors to provide a safer environment for their workers: The majority of work can be carried out above ground (caisson method). Overhead services hazards are minimised as no large cranes are required. The system has a built-in safety barrier created by the installation of the top ring.
sizes in one piece and segmental shafts: 2.4 m one piece shaft 3 m one piece shaft 3.6 m one piece shaft 4.5 m segmental shaft 6 m segmental shaft 7.5 m segmental shaft 9 m segmental shaft 10.5 m segmental shaft 12.5 m segmental shaft 15 m segmental shaft Sizes up to 25 m are also available, please contact
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).
Humes for availability.
Construction methods
There are three techniques available to install a precast concrete segmental shaft. These are the caisson method, underpin method and the last method is a combination of the two. The design of caisson and underpin shafts requires specialist skills and should be executed by a designer experienced with these construction methods.
Top: Caisson method of shaft installation showing hydraulic jacks (gallows) Bottom: Bottom/choker ring with steel cutting edge
Caisson method
The caisson method is generally used in softer soils with or without the presence of ground water. Caisson are either installed as a wet caisson where the water level inside the caisson is slightly higher than the external ground water level, or as a dry caisson where the inside of the caisson is open to the atmosphere. In the caisson method, the precast concrete elements are erected at the surface and are then lowered into the ground whilst excavation progresses. There are a number of common features unique to Humes' caisson shaft systems which facilitate installation. These are: In-situ cast concrete collars These collars act as a guide ring to keep the caisson shaft vertical and, in larger diameter shafts, resist the force from the hydraulic jacks. Hydraulic jacks (gallows) These are installed to both steer the shaft and to add to the vertical force in addition to the self weight of the shaft lining (generally not required for one piece rings). Excavation should be slightly larger in diameter than the precast concrete shaft The annulus between the shaft and the excavated ground should be filled with suitable fluid (usually bentonite with additives as required to suit the ground conditions) which acts both as a lubricant but also supports the ground during installation. The bottom/choker ring is wider than the standard ring and the same diameter as the excavation The choker ring is designed to provide a seal diameter between the shaft and excavated ground so that the fluid in the annulus above the ring is retained. The choker segments are also designed to bolt the steel cutting edge to the shaft and connect the underpin segment. Refer to combination method on page 11. A steel cutting edge underneath the bottom/choker ring The steel cutting edge literally cuts through the ground. An additional function is that it acts as a stiffener. All caisson units are provided with grout sockets This allows the exterior annulus to be filled with a cementitious grout at completion of the installation.
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.
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Combination of the caisson and underpin methods

A combination of both methods can be used if the soil condition varies. Installation commences with the caisson method (using a special choker ring) and then shifts to the underpin method when the hard soil ground is reached. A special choker/transition ring must be used to enable the shift to the underpin construction method. 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.
Right: Combination method of shaft installation
Figure 7 Combination method details
Caisson rings
Tie rod Choker ring
Underpin rings Double eye bolt
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Typical ring configuration

One piece shafts
One piece caisson units are ideally suited for construction of sewage pump station wet wells, access chambers for large diameter pipelines and jacking launch or receival shafts for small diameter microtunnelling. One piece shafts can be supplied in a range of diameters but standard sizes are as detailed in Table 2 below.
Table 2 Standard one piece caisson units* Nominal diameter (DN) 2,400 3,000 3,600 Internal diameter (mm) 2,374 3,060 3,600 External diameter (mm) 2,782 3,460 4,000 Height of standard units (mm)* 1,000 1,000 1,000 Mass of standard units (tonnes) 4.3 5.2 6.0
Number of tie rod couplers 6 8 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
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Joint and connection details Horizontal joints between one piece caisson units are sealed with both a hydrophilic rubber seal near the external surface and a butyl mastic rubber seal near the internal surface. For temporary installations, a single butyl mastic seal is likely to be sufficient. In addition, units come complete with a groove on the inside face which allows caulking of the internal surface. Horizontal joints between one piece caisson rings are connected with vertical tie rods that are mainly provided for temporary loads during installation. These rods are normally made from galvanised steel. For permanent installations, it is recommended that approximately half of these rods and couplers be replaced with stainless steel so that the hydrophilic seal is confined during the life of the structure.
Special units Special units include the following: Panelled rings which include recesses, are designed to provide a shear connection between the precast concrete shaft and an in-situ cast concrete plug, installed to prevent flotation. Either single or multiple panelled rings are particularly effective for wet caissons where the connection plug will be cast prior to de-watering. Rings with corrosion protection linings (either High Density Polyethylene (HDPE) or Plastiline - Polyvinyl Chloride (PVC)) for added corrosion resistance. Soft eye rings are applied to small diameter (DN600 or less) microtunnelling applications. Rings can be provided with either reduced or no steel reinforcement at pipe penetrations. Cover slabs incorporating openings and/or lids as required. The joint and connection details for the standard rings are included with these cover slabs.
Left: One piece shaft Right: Cover slab
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Segmental shafts
Where shaft diameters exceed the size of the one piece ring '3.60 m ID', the segmental shaft system comes into its own so that shafts of almost any diameter can be constructed. A ring consists of a series of ordinary segments which have four edges that are perpendicular to each other and two tapered segments (left and right) which have one tapered end which allows for closing of the ring by simply lowering the last (tapered right) segment into position. Number of segments per ring varies depending on the shaft diameter (refer to Table 3 below).
Figure 9 Installing tapered segments to close the ring
Tapered left segment
Tapered right segment Ordinary segment
Table 3 Standard segmental shaft details Internal diameter (m) 4.50 6.00 7.50 9.00 10.50 12.50 15.00 External diameter (m) 4.90 6.45 7.95 9.50 11.00 13.15 15.75 Segments per ring Height (m) 1.00 1.00 1.00 1.00 1.00 1.00 1.00 Ordinary 5 7 8 12 12 14 16 Tapered 2 2 2 2 2 2 2 Mass per ring (tonnes) 7.36 10.78 13.37 17.80 25.40 32.80 44.50 Mass per segment (kg) 1,050 1,200 1,340 1,270 1,820 2,050 2,500
Note: Diameters up to 25 m are also available, contact Humes for availability.
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Joint and connection details A unique external fixing is used to join the smooth segmental shaft. The strong connection bolts together the segments to form a ring. Subsequently, the rings come together to form a shaft. The system retains all the benefits of strength, flexibility and speed of erection whilst providing the client with a safer shaft construction system. Cross joints Segments are connected across this joint using curved bolts (refer to Figure 10 below) which are installed from the outside for caisson installation and from the inside for underpin installation (see photos).
Top: Curved bolt fitting caisson installation Bottom: Curved bolt fitting - underpin installation
Figure 10 Curved bolts used for cross joints
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Circle joints Caisson segmental rings are connected using vertical tie rods that extend through the full length of the segments (refer to Figure 11 and 12). Underpin segmental rings are connected using a double eye bolt arrangement that allows the joint to be tightened from inside the shaft (refer to Figure 13 below). All bolts used with segmental shaft construction are made from galvanised steel and are only necessary to support the shaft during the installation. Once segmental shafts have been grouted into position the bolts are redundant.
Figure 11 Jointing details (caisson segment)

Conduit for tie rod Grout socket assembly
Curved bolt hole recess
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
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Special units Special rings and/or segments can also be supplied in addition to the standard segmental shaft caisson rings: Panelled rings Recesses can be included in both standard rings and choker rings as required. As with the one piece caisson rings these are intended to provide a shear connection between an in-situ cast plug or base slab and the segmental shaft. It is recommended that complete panelled ring(s) are installed. Soft eye rings Standard segments are reinforced with steel reinforcing bars. It is possible to provide rings with some segments manufactured using fibre reinforcement located at pipes penetrations for microtunnelling applications. For the caisson method, a complete ring of fibre reinforced segments is not recommended. Figure 14 Grout socket assembly
Threaded grout plug Sealing washer
Top: Panelled ring Bottom: Segment packing and detail of stacking spacer
Innovative features Grout socket assembly Each segment and ring is fitted with a plastic grout socket assembly which includes a non-return valve. The assembly is used to introduce bentonite slurry between the caisson ring and the soil, to lubricate and reduce friction force while jacking rings into the ground. The same socket is used to inject grout to permanently secure the rings. For underpin installations the socket is also used to secure the segment into the underpin lifting frame (refer to page 10). Packing Bituminous felt packing of 3 mm nominal thickness is used on all longitudinal joints. The packing is designed to prevent direct contact between concrete surfaces as a result from compressed forces imposed by the surrounding soil. 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.
Detail Non-return valve Grout/Lifting socket
17
30
Load-deflection graph Figure 15 Load deflection graph

60 55 50 45 Load (kN/m) Load (kN/m) 40 30 25 20 15 10 5 0 35
TUNNEL SEGMENT GASKET TYPE JS1
GAP
26 10 mm offset
0 0 1 1 2 2 3 3 4 4 5 5 6 6
30
7 7 8 8 8 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 Deflection (mm) Deflection(mm)
Water Figure 16 Watertightness graph tightness graph

10/05
12 11 10 9 8
7
Trelleborg Bakker B.V. tel: +31 180 495 555, fax: +31 180 433 080
Pressure (bar) Pressure (bar)
6 5 4 3 2 1 0 0 0 1 1 2 2 3 3 4 4 5 5
Gap (mm) Gap
6 6
6.5 7.5 6.5

7 7 8 8
10.25
9 9
10 10
10/05
Trelleborg Bakker B.V. tel: +31 180 495 555, fax: +31 180 433 080
Detail
10.25 Gap 10 mm offset 26 30 Right: Ethylene Propylene Diene Manomer gasket placement and detail 18 Tunnel and shaft solutions
6.5
7.5
6.5
3-pin precast arches

Humes' precast arch system is a high performance and cost effective tunnel solution. A large range of custom designed 3-pin arches have been developed which are ideal for a variety of complex heavy loading criteria and internal envelopes. A wide range of 3-pin arches have been used for reclaim tunnels in mining applications. They are designed to suit coal and other mineral stockpiles up to 45 metres. The 3-pin arch is a soil-structure interaction system where the backfill of the specified zone contributes to the load carrying capacity of the arch and becomes part of the structure. Its optimised geometry and the unique pinned joint allows it to bear and pass heavy load to the foundation.

Designed to meet the mines designated design life and can exceed 100 years. Delivered in segments to suit light cranes. Require minimal maintenance since: - the combination of backfill and overfill protects the arch element - it has no exposed metal nor bolting system. Openings for ventilation, escape accesses and intake valves can be easily accommodated. Grades and curved tunnels can be achieved using the same type arch profile. A unique jointing system without any overlapping, staggering, bolting or cast in-situ joints. Self supported during installation, does not require scaffolding or support of backfill. Easy to clean and maintain as conveyor belts can be attached to the internal soffit of the arch allowing sufficient clearance for service vehicles to pass beneath. Fewer units are required for installation as most arch units are 1.8 m to 2.5 m wide. Arches can be installed with minimum disruption to conveyor operation.
Applications
Reclaim tunnels Conveyor tunnels Escape tunnels Underpasses
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Product range
Humes 3-pin arches are custom-made to suit specific project requirements. They are designed to accommodate the defined envelope, where the function of the tunnel and loads are applied. Humes in-house design team can assist in choosing the most economical 3-pin arch profile (some standard profiles are shown in Figure 17 below). We will conduct both linear and non-linear 3D analysis to define structure suitability, an example of this is shown in Figure 18 below.
Figure 17 3-pin arch profiles

11,000 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 0 8,000 7,000 6,000 5,000 2,000 1,000 1,000 2,000 3,000 4,000 5,000 6,000 7,000 4,000 3,000 8,000 0
Figure 18 3D design analysis
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Arch system components

A range of precast concrete products are usually provided as part of the arch structure along with a selection of retaining wall structures including: precast concrete feeder chambers to fit intake valves spandrel walls which run parallel to the arch, retaining the backfill at each end of the tunnel. They are designed to match the arch profile. wing walls which are placed at each end of the spandrel wall to retain the backfill and support the spandrel walls.
Top: Arch system with spandrel wall and wing walls Middle: Spandrel wall Bottom: Wing walls
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Box culverts
Top and bottom: Construction of a box culvert mine portal Opposite page: Jacking pipe
Humes manufactures extra large span box culverts with spans and leg heights up to 6 metres. For additional strength, prestressed units and post-tensioning are also available. A complete precast base and crown unit can be supplied for fast and easy installation. This will minimise the need for cast in-situ concrete, especially for remote mining sites. Box culverts can also be jacked underneath railways and roads or slid into a pre-excavated tunnel.
Applications
Portal entries - provide safe ingress and egress for mine and construction sites Conveyer tunnels Escape tunnels Railways and roads Drainage for haul roads

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.
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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
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Benefits of pipe jacking

Technical
Inherent strength of lining. Smooth internal finish giving good flow characteristics. No requirement for secondary lining. Considerably less joints than a segmental tunnel. Prevention of ground water ingress by use of pipes with sealed flexible joints. Provision of invert channels in larger pipes to contain the dry weather flow of a sewer in a combined system.
Economic
Less affected by weather condition Less risk of settlement Minimal surface disruption Minimal reinstatement Reduced requirement for utilities diversions in urban areas
Environmental
There are substantial environmental benefits to be gained by the use of pipe jacking techniques when compared with the traditional open trench approach:
Safety
Pipe jacking is an inherently safer method than open trench construction or when considering the risks associated with deep, large section, open excavations: Major reduction in man-hours, opportunities for accidents to occur are less with pipe jacking. In busy urban centres, trenchless operation will not interfere with pedestrian and motor traffic movements. There is significant reduction in the risk of injury as a result of utility strikes and interface with the public. Less risk of settlement.
Typically the trenchless method will reduce the quantities of incoming and outgoing materials, with a consequent reduction in tipping of spoil and quarrying of imported stone fill. This in turn leads to reduced vehicle movements and subsequently less associated disruption. Minimal surface disruption and reinstatement. Trenchless will not harm existing vegetation. Noise, dirt and smell are minimised.
Source: An introduction to pipe jacking and microtunelling design Pipe Jacking Association UK
Figure 19 Typical pipe jacking set up
Detail Intermediate jacking station Rubber rings Timber joint packer Lead pipe (steel can)
Trail pipe
Jacking direction
Jacks
Crane to lower pipes into position
Standard pipe Lubrication port
Thrust ring Standard pipe
Jacking direction
Working face with jacking shield
Launch shaft with hydraulic jacks
Intermediate jacking station to assist longer drives
Receival shaft
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Steel reinforced concrete pipes (SRCP)

Humes is Australias leading manufacturer of SRCP. We have a wide range of diameters, lengths and strengths available. Our SRCP has a proven track record and can be custom designed for applications such as drainage, sewage, water supply and irrigation. A milestone was achieved when Humes' DN2100, fixed steel collar pipes were jacked 1,030 m without any intermediate shafts on the Northern Pipeline Interconnector Stage 2, SEQ (refer to our case study on this project for further details).
Durable Humes SRCP has a number of concrete properties that influence long service life. These properties are: Ultimate compressive strength: Humes SRCP compressive strength is usually in the range of up to 60 MPa and above. The strength of the pipe is a result of the materials used in the concrete mix, the mix design, manufacturing techniques and the curing process. Low water absorption, below 4%, due to the density and impermeability of the concrete used and manufacturing process. AS/NZS 4058-2007 specifies a maximum allowable absorption of 6% for all concrete pipes. A low water/cement (W/C) ratio of below 0.35. The
Benefits of reinforced concrete jacking pipes

Optimal strength Humes SRCP are manufactured and factory tested for quality to AS/NZS 4058:2007 "Precast concrete pipes (Pressure and Non-pressure)": A concrete pipe is a rigid pipe system that relies mostly on the strength of the pipe and is only slightly dependent on the strength derived from the soil envelope. The inherent strength of concrete pipe can compensate for site problems not designed for, such as construction shortcomings and higher fill heights and trench depths. Concrete pipes are less susceptible to damage during construction, and maintain their shape by not deflecting. All concrete pipe strengths are standardised by AS/NZS 4058 Precast Concrete Pipes. Concrete pipes are strength-tested by the manufacturer to proof loads, or test loads, as nominated by the standard for particular diameter and class. Steel reinforcement in concrete pipes adds significantly to their inherent strength. The steel reinforcement is shaped into cages by automatic cage welding machines. The machines ensure that the reinforcement cages are dimensionally correct and have tight enginereed tolerances.
W/C ratio is considered a trademark for durable concrete pipe, particularly as high compressive strength is related to this criterion. High alkalinity is controlled by cementitious content maintained by a proper mix design, material properties as well as the manufacturing and curing process. Concrete pipe aggregates, both coarse and fine, meet the requirements of AS 2758. Aggregates are a key element in producing quality concrete and in turn, quality pipe.
Source: Concrete Pipe Facts, Concrete Pipe Association of Australasia, www.cpaa.asn.au/concrete-pipe-facts.html
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Fixed steel collar pipes

A wide robust range is available from DN300 to DN3000 inclusive. They are a custom designed reinforced concrete jacking pipe incorporating a single wide jacking face including timber packers, a secure steel collar cast onto the pipe and a flexible watertight joint. All these being essential for longer pipe jacks and unstable ground conditions.
Elastomeric seal The elastomeric seal is located with the corrugated steel collar in the S type collar band, factory secured internally to the steel socket band with adhesive. While, in the J type the seal is retained within the accurately formed recess on the pipe spigot. Both unique designs will ensure that the elastomeric seal remains in place in compression even if joint deflection occurs. The joint integrity remains intact when subjected to either internal or external hydraulic pressure. A muck ring is fitted within the J type joint; limiting the ingress of soil into the joint during jacking. The muck ring will be compressed by the end of the steel collar.
Applications The fixed steel collar jacking pipes provides high axial load transfer capacity and a flexible watertight joint. This is the ideal jacking pipe for all stormwater, sewerage, sleeve pipe and jacked low pressure pipeline applications.
Watertight joint (External pressure testing) Steel collar types Humes have undertaken external pressure testing of Humes offer two different types of fixed steel collars: the S type which is fitted into pipes up to DN700 and the J type fitted into remaining sizes (mainly from DN800 to DN3000). The steel collar bands are fabricated to high tolerances to ensure optimum joint performance. Both steel collars include a water stop hydro-seal to prevent ingress of water between the band and the concrete pipe wall. 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. deflected joints with external hydrostatic pressures up to 400 kPa without visible leaks. On this basis, fixed steel collar jacking pipes are rated for 250 kPa external pressure for the joint deflections shown in Figures 22 and 23 on page 29. Humes can design pipes for higher external pressure ratings if required.
Figure 20 S type joint profile
Figure 21 J type joint profile
26
Inert thermoplastic linings Humes are able to supply the J type steel collar jacking pipes complete with corrosion protection linings (either High Density Polyethylene (HDPE) or Plastiline- Polyvinyl Chloride (PVC)) in accordance with Water Services Association of Australia (WSAA) standard specification WSA113. These linings are a proven method of concrete protection against H2S attack in trunk sewers.
if required by the project designer for isolation of the joint from the pipeline environment (see Figure 21 on page 26). The combination of mild steel collars with internal joint gap sealant can provide a cost effective solution in certain ground conditions.
Intermediate jacking stations Humes have standard designs for intermediate jacking stations and these include trail and lead pipes for all
Secondary sealing recess All J type steel collar jacking pipes are supplied with a recess on the internal pipe ends which allows for locating a flexible sealant, applied internally after installation,
diameters DN1000 to DN2000. The arrangement of these pipes at the intermediate jacking station is shown in Figure 19 on page 24.
Table 4 Features and benefits Features Elastomeric seal Benefit to asset owner Watertight joint Prevents ingress or egress of water and soil surrounding the pipes and allows pressure grouting of the excavated annulus at the completion of jacking (if required). Collar material The designer has many options for the grade of steel to suit the intended design life in the installed environment of the pipe. Generally, mild steel is considered suitable for in-ground conditions and a non-aggressive environment. Permanent seal location The seal remains in place throughout the design life of the pipeline providing a long-term watertight structure under external groundwater pressures or ground movement. Efficient construction Long drives, lower construction costs and less disturbance to above-ground activities. Maintain watertight joint After installation the muck ring protects the rubber ring and the steel collar to maintain watertightness. Additional sealing options The recess is shaped to allow retention of a flexible sealant if secondary joint sealing is required. Benefit to contractor 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. 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. Restrained seal Ensures that the seal remains in place during jointing and jacking with external pressure from groundwater or lubrication injection. Long drives The wide face on the pipe end enables transfer of high jacking forces through the centerline of the pipe wall enabling accurate steering and long drives. Maintain watertight joint Prevents ingress of soil into joint during jacking.
Steel collar fixed to pipe with in-built water stop
Corrugated collar recess (S type) Deep spigot groove (J type) Single wide jacking face
Muck ring (J type)
Internal joint recess
No spalling Prevents spalling of inside concrete face if the packer is displaced during jacking.
27
Optimal strength Humes fixed collar jacking pipes, both with S and J type collar, are designed with steel reinforcement placed for optimal strength, which combined with the strength and durability of Humes concrete pipes, provides an excellent jacking pipe. Steel reinforced concrete jacking pipes are capable of withstanding higher jacking loads.
Jacking design and forces The Concrete Pipe Association of Australasia (CPAA) publication, Jacking Design Guidelines is a recommended guide to calculate and define jacking forces. The guide can be downloaded by visiting; www.cpaa.asn.au/CPAA-Online-Shop.html Jacking forces and lateral displacement off line and
The jacking load capacity of standard pipes for a range of joint deflections is illustrated in Figures 22 and 23 on the following page. Pipes with higher jacking loads and/or joint deflections can be designed for specific projects.
level have to be recorded at regular intervals of jacking distance (not exceeding 200 mm or every 90 seconds). Ensure that jacking forces are maintained within the limits specified in Figures 22 and 23 on the following page. If circumstances cause a jacking force/deflection combination outside of these limits, hold the jacking operation and contact Humes for assistance.
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Figure 22 S type 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 type jacking pipes deflection curves

J Series Jacking Pipes 2500 2,500 2250 2,250 2000 2,000
Maximum jacking force (tonnes) Maximum Jacking Force (Tonnes)
1750 1,750 1500 1,500
1250 1,250 1000 1,000 750 750 500 500 250 250
0 0 0.10 0.10
0.20 0.20
0.30 0.30
0.40 0.40
0.50 0.60 0.70 0.80 0.50 0.60 0.70 0.80 Maximum Joint De deflection (degrees) ection (Degrees) Maximum joint DN1200 DN1350 DN1500 DN1650
0.90 0.90
1.00 1.00
1.101.10
1.20 1.20
DN800 DN2700
DN900 DN3000
DN1000
DN1100
DN1800
DN2100
DN2400
DN2500
DN800 DN1650
DN900 DN1800
DN1000 DN2100
DN1100 DN2400
DN1200 DN2500
DN1350 DN2700
DN1500 DN3000
29
Table 5 Fixed steel collar pipes dimensions, mass, jacking loads and deflections
Swiftlift anchors T
C t Pw Pt Detail D A B
Nominal diameter 300 350 400 450 500 600 700
Internal diameter 'A' (mm) 300 350 400 450 500 600 700
External diameter 'B' (mm) 430 480 540 606 672 774 876
Wall thickness 'T' (mm) 65 65 70 78 86 87 88
Effective length 'L' (mm) 2,400 2,400 2,400 2,400 2,400 2,400 2,400
Min. joint packer 'Pt/Pw' (mm) 3/40 3/40 3/40 3/40 3/40 6/60 6/60
Steel collar Length 'C' (mm) 50 50 50 50 50 80 80 ID 'D' (mm) 412 462 522 588 654 752 854 Thickness 't' (mm) 1.5 1.5 1.5 1.5 1.5 2 2 Pipe mass (kg) 500 550 660 725 1,000 1,190 1,380
Max. jacking load (tonnes) 100 115 135 165 225 240 280
Collar type S S S S S S S
800 900 1,000 1,100 1,200 1,350 1,500 1,600 1,650 1,800 2,100 2,400 2,500 2,700 3,000
800 900 1,000 1,100 1,200 1,350 1,500 1,600 1,650 1,800 2,100 2,374 2,500 2,636 2,972
1,000 1,110 1,220 1,332 1,450 1,626 1,800 1,940 1,974 2,150 2,500 2,783 3,000 3,096 3,472
100 105 110 116 125 138 150 170 162 175 200 204 250 230 250
2,360 2,360 2,360 2,360 2,360 2,320 2,320 2,985 2,320 2,320 2,985 2,985 2,985 2,985 2,985
12/65 12/70 12/75 12/80 12/90 16/90 16/100 16/110 16/110 16/125 16/160 16/175 16/195 16/175 16/195
120 120 120 120 120 160 160 160 160 160 160 175 175 175 175
989 1,099 1,209 1,321 1,439 1,611 1,785 1,911 1,959 2,135 2,481 2,759 2,977 3,073 3,449
4 4 4 4 4 6 6 8 6 6 8 10 10 10 10
1,800 2,100 2,400 2,800 3,300 4,000 4,800 7,500 5,700 6,700 12,050 12,950 16,650 16,150 19,700
500 500 515 565 650 755 840 1,020 925 1,050 1,440 1,485 2,000 1,900 2,220
J J J J J J J J J J J J J J J
30
Loose steel collar pipes

Humes offer two types of loose steel collar SRCP jacking pipes, butt joint and in-wall joint. They are available from DN300 to DN3000 (standard range DN300 to DN2100). The steel collar is not attached to the pipe (cast with) but rather is fitted onto the pipe before installation. The collars can be supplied by either Humes or the contractor.
In-wall joint pipes In-wall joint jacking pipes are available from DN1200 to DN3600 (standard range DN1200 to DN2100). In-wall joint jacking pipes incorporate a concrete socket formed in the wall of the pipe, a rubber ring located on the pipe spigot and timber packers on one or both joint faces (see Figure 25). Applications In-wall joint jacking pipes are an economical viable alternative for typically short length applications where a flexible watertight joint is required, however, this type of joint can have limitations in jacking load transfer. A J type pipe should be specified in these situations.
Butt joint pipes Butt joint jacking pipes incorporate a single wide jacking face. External recesses at each end of the pipe allow for a rolled steel collar to be located between adjacent pipes, providing the necessary shear connection (see Figure 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

Steel collar
Figure 25 In-wall joint profile

Steel collar
31
Table 6 Loose steel collar pipe range In-wall joint Nominal diameter Internal diameter External diameter mm DN300 DN375 DN475 DN525 DN600 DN675 DN750 DN825 DN900 DN975 DN1050 DN1200 DN1350 DN1500 DN1650 DN1800 DN1950 DN2100 1,920 2,088 2,220 2,388 1,200 1,500 280 363 438 518 586 653 730 790 875 951 1,026 1,163 1,324 1,452 1,596 1,756 1,930 2,096 362 445 534 616 698 781 864 946 1029 1,111 1,194 1,359 1,524 1,676 1,842 2,006 2,198 2,388 Butt joint Internal diameter External diameter
Notes: 1. Alternative internal diameters (and external diameters) may be available to suit project 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

The most basic requirements for all jacking pipes is that they must be capable of supporting the excavation (earth and traffic loads), transferring axial load, providing a shear connection between adjacent pipes and joint flexibility that allows for each pipe to follow the path excavated in front of the shield.
In addition, jacking pipes may need to prevent ingress of surrounding soil, groundwater, lubricants or grouts and provide a joint capable of withstanding internal pressure in sewerage or pressure pipeline applications. Jacking pipes must meet both the needs of the contractor and asset owner who is usually represented by the pipeline designer. Table 7 opposite provides a summary of the capabilities of each of our types of jacking pipes for different requirements and applications.
32
Table 7 Selection of jacking pipes Jacking pipe requirements or application Standard size class Extended diameter range* Incorporation of inert thermoplastic lining External grouting Internal pressure test capability (kPa) Application of internal secondary sealants Sewerage pipelines Stormwater pipelines Road and rail culverts Sleeve pipe applications Asset owners and contractors Length of jacked pipeline (m) External pressure test capability Jacking force transfer Intermediate jacking stations pipes Contractors Open face shields Closed face pressure shields Lubrication along length of pipeline Fixed steel collar S type DN300 DN700 DN800 N/A Suitable for short lengths 90 N/A J type DN800 DN3000 Up to DN3600 Available Ideally suited 150 Suitable Loose steel collar Butt joint DN300 D2100 DN2250 DN3000 DN900 > Not suitable N/A Not suitable In-wall joint DN1200 DN2100 DN2250 DN3600 Available Limited suitability 90 Limited suitability
Stakeholder Asset owner
Limited suitability|| Ideally suited Ideally suited Ideally suited 0 50
Ideally suited Ideally suited Ideally suited Ideally suited < DN1000: 0 150 DN1000 DN3000: no limit 250 Excellent Available DN900 DN3000 Suitable Ideally suited Ideally suited
Not suitable Limited suitability Limited suitability Limited suitability# 0 50**
Suitable Suitable Suitable Suitable 0 50
90 Excellent N/A Suitable Ideally suited N/A
N/A Good To be provided by contractor Suitable Not suitable Not suitable||||
90 Moderate To be provided by contractor Suitable Limited suitability Limited suitability
Notes: * Refer to Humes for availability. Grout pressures need to be carefully monitored. Test to AS/NZS 4058: 2007. Higher pressures are possible with certain diameters refer to Humes for advice if higher pressures are required. || If corrosive sewage gases are expected consider using 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
Load class Jacking pipes, as opposed to pipes laid in open excavations, are subjected to both jacking forces, external earth loads and life loads (permanent loads) and all of these have to be considered when specifying the pipes. The effect of the jacking force on the pipe barrel is small on account of the high compressive strength of the concrete. The joint, however, must be considered because the joint cross-section is smaller, as a rule, than that of the barrel and the jacking force is transferred eccentrically across the joint. The external earth load on the barrel is equal to or smaller than the trench load on a pipe bedded in a trench of same width as the excavation (i.e. the outside diameter of the pipe plus a margin for over-excavation). The jacking method of installation, therefore, is very efficient from an external load point of view since the external earth load is smaller than both trench and embankment load on pipes of the same diameter under the same height of fill.
The higher value is recommended when the annulus between the pipe and ground is grouted. Grouting of this annulus with a suitable cementitious grout is recommended in most installations as any voids could create a drainage path external to the pipeline which in turn could lead to soil erosion, lowering of ground water tables and, in aggressive soil conditions, an increased risk of corrosion of pipe materials. The axial loading from the pipe jacking is not directly included in the selection of the pipe load class. Timber packers are placed between the jacking faces of the concrete pipes to avoid high stresses that could result from direct concrete to concrete contact. The axial load capacity of the concrete pipe is determined based on the minimum pipe wall thickness, concrete strength, properties of the timber packers and the deflections that can be expected at pipe joints during installation. The allowable jacking forces and associated maximum joint deflections are calculated in accordance with the Concrete Pipe Association of Australasia (CPAA) publication, Jacking Design Guidelines.
Source: Jacking Design Guidelines, Concrete Pipe Association of Australasia.
As such a minimum Class 4 pipe is usually recommended although in some short length drives a Class 3 may be suitable. The Class 4 pipe to Australian Standard AS/NZS 4058: 2007 has very similar strength requirements to load classes specified for jacking pipes in European and Japanese Standards. AS/NZS 4058: 2007 outlines the technique for determining the permanent vertical loads acting on pipes installed using pipe jacking. The jacking pipe is installed underground into undisturbed natural ground where the soils natural cohesion contributes to arching over the pipe. Where the calculation includes the effects of arching due to soil cohesion extensive soil investigations should be carried out to determine the appropriate design soil properties. The jacking installation results in a recommended bedding factor between two and three that is used to determine the minimum suitable pipe class required due to permanent loads. Ensure that jacking forces are maintained within the specified limits. If circumstances cause a jacking force/ deflection combination outside of these limits, hold the jacking operation and contact Humes for assistance. Jacking force and lateral displacement off line and level have to be recorded at regular intervals of jacking distance (not exceeding 200 mm or every 90 seconds). The CPAA publication, Jacking Design Guidelines, is a recommended guide to calculate and define jacking forces. The guide can be downloaded by visiting; www.cpaa.asn.au/CPAA-Online-Shop.html Jacking design and forces
34
Vitrified clay pipes

Humes vitrified clay jacking pipes are manufactured by STEINZEUG-KERAMO (STEINZEUG Abwassersysteme GmbH) and inspected in accordance with the European standard for vitrified clay pipes, fittings and joints for drains and sewers - EN 295.
Strength in the length direction is the most important factor for jacking pipes, because they must withstand the high jacking forces necessary to overcome the resistance of the cutting face and the external pipe surface. According to the EN 295 standard, the longitudinal compressive strength of the surfaces that transfer the force between pipe sections must be at least 75 N/mm. STEINZEUG-KERAMO guarantees a value of at least 100 N/mm. That is higher than the values stated for other types of current jacking material. It allows very high jacking forces to be used, although this capability is only partially utilised in practice. The glazed outer surface of the pipe strongly reduces friction between the pipe and the surrounding soil.

Watertightness The joints are tested in accordance with EN 295, which means that they are guaranteed to be watertight at 0.5 bar, including the angular deflections and radial loads specified in the standard. They are also tested in accordance with ZPWN 2951 and ATV A142, with guaranteed watertightness at 2.4 bar. Watertightness is also tested at an external pressure of 6 bar, which provides a high level of security against penetration of soil slurries and bentonite.
High abrasion resistance Vitrified clay has high abrasion resistance, which is equally true for the glaze and the rest of the wall. Abrasion values encountered in the tests are approximately 0.08 mm, which is much lower than the typical abrasion values of 0.2 mm to 0.5 mm after 100,000 load cycles measured using the Darmstadt test as specified in the EN 295 standard or the maximum value of 0.25 mm in the ZPWN 295 standard. Abrasion does not accelerate even with extended load cycles, such as up to 400,000, in contrast to what is often suggested in data sheets for competitive materials. The depth of abrasion remains limited to 0.3 - 0.8 mm after 400,000 cycles. Compared with the large wall thicknesses of vitrified clay jacking pipes, that represents a negligible loss of wall thickness.
Corrosion resistance Vitrified clay material is resistant to all types of chemicals over the entire wall thickness. The resistance of the vitrified clay material and seals is tested using chemicals, including sulphuric acid at pH 0 and NaOH at pH 14, in conformance with EN 295 and ZPWN 295.
High mechanical strength Vitrified clay jacking pipes generally have greater wall thicknesses than corresponding standard vitrified clay sewer pipes, that results in high crown pressure ratings and high resistance to ground and traffic loads.
1. ZPWN 295 is an internal manufacturer standard of STEINZEUG-KERAMO.
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
Product range
The entire range of vitrified clay jacking pipes DN200 to DN1200 are fitted with a stainless steel coupling which has a high chrome and nickel content and a relatively significant molybdenum content. This coupling is highly resistant to corrosion in aggressive soils (acids, chlorides and halogens). Two different types of stainless steel couplings are used, Type 1 and Type 2.
DN400 to DN1200 with Type 2 stainless steel coupling The moulded rubber seal is integrated in a milled groove. The packing ring, which transmits the jacking force, is made from particle board and is prefitted to the coupling. Pipes are sawn and milled at both ends to yield parallel end faces. For diameters DN600 and above a clamping (prestressing) ring is fitted at each spigot end. This ring increases the permissible jacking force and provides additional protection in case of poorly controlled steering motions during jacking or when angular deflections occur due to variations in soil conditions. Intermediate re-usable jacking stations can be used with diameters of DN600 and above. This is advisable for long jacking distances and when jacking forces exceeding the specified limits are anticipated. The intermediate jacking stations are coupled to the spigot ends of the pipes and recovered in the receival pit or an intermediate shaft.
DN200 to DN300 with Type 1 stainless steel coupling The moulded elastomer seal is integrated into the ring. The packing ring, which transmits the jacking force is made from elastomer for diameters up to DN300 and forms a unit with the moulded sealing ring. Pipes are sawn at both ends to yield parallel end faces. The spigot ends are milled. The precision ground safe internal working pressure of 2.4 bar. The sealing capabilities of the coupler due to its special design not only guarantees joint integrity, but ensures full protection from the ingress of matter during the jacking process. spigots as for larger dimension jacking pipes permit a
The trenchless mode of construction
Figure 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
Detail 2 2
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. jacking force* Min. crushing load
Pipe dimensions DN Internal d1

5
Coupling Length l1
1
Pressure transfer ring b dz

1
Average weight
Pipe end d3
Pipe body dM
dk
1
k 0.2
k 1.5
za 0.5
zi 0.5
kN
kN/m
kg/m
mm 200 199 244

+2 -2
276
+0 -6
990 990 1,990 990 1,990
49
+3 -1
267.8
1.5
103
10
241
205
350
80
60
250
250
322
+0 -1
360
+0 -6
48
+3 -0
342.8
1.5
106
10
320
257
810
110
105
300
299
374
+0 -1
406
+0 -10
48
+3 -0
395.8
2.0
106
10
372
309
1,000
120
125
Notes: 1. * Permissible jacking force for automatic recording and control, safety factors 2 and 1.6. 2. Compressive strength = 100 N/mm2. 3. Bending tensile strength = 14 N/mm2. 4. Supplied with wooden pressure transfer ring according to EN 312 P5. 5. The ground spigot ends (d3) are trimmed ca. 2 x 2 mm.
38
Figure 28 Joint profiles for DN400 to DN1200 pipe with Type 2 coupling
Bevel dm min. 45
e Rubber seal bk Max. dm on this side
dz d1 d3 dM dk dza dzi
Particle board
Prestressing ring6
l1
Sk Jacking direction
Table 9 Dimensions for DN400 to DN1200 pipe with Type 2 coupling (refer Figure 28 above) Pressure transfer ring bk
1
Pipe dimensions Internal d1 DN Pipe end d3

+0 -1
Coupling Length l1
1
Max. jacking force*
Min. crushing load
Average weight
Pipe body dM
e
2
dk
1
sk
0.2
dz
1
dza
1
dzi
1
kN
kN/m
kg/m
mm 400 500 600 700 800 1000 1200 400 498 599 695 792 1,056 1,249
+6 -6 + 7.5 - 7.5 +9 -9
528 632 723 827 921 1,218 1,408
556 661 766 870 970 1,275 1,475
+0 - 12 +0 - 15 +0 - 18
984 1,984 1,984 1,981 1,981 1,981 1,981 1,981
65 65 70 70 70 70 80
536 640 731 837 931 1,230 1,422
3 3 3 4 4 5 6
130 130 143 143 143 143 163
16 16 19 19 19 19 19
518 624 713 816 911
413 513 615 715 823
2,350 3,000 3,100 3,300 3,700 5,700 6,400
160 140 120 140 128 120 114
240 295 350 434 507 855 990
+ 12 - 12 + 12 - 12 + 15 - 15 + 18 - 18
+0 - 24 +0 - 24 +0 - 30 +0 - 36
1,208 1,077 1,397 1,277
Notes: 1. * Permissible jacking force for automatic recording and control, safety factors 2 and 1.6. 2. Compressive strength = 100 N/mm2. 3. Bending tensile strength = 14 N/mm2. 4. Supplied with wooden pressure transfer ring according to EN 312 P5. 5. The ground spigot ends (d3) are trimmed ca. 2 x 2 mm. 6. For diameters DN600 and above a prestressing (clamping) ring is 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 29 Adaptor pipe for DN200 to DN600 pipes

bk e = 180 mm Coupling type 1 or 2
Figure 30 Connection of adaptor pipe to access chamber

Grinded on a length e = 180 mm BKK ring P ring
dz dk d1 d3 dM d3 of the jacking pipe d3 of the standard vc pipe (normal or high strength)
dM
1,000 mm
1,000 mm Inspection chamber with vitrified clay invert
Table 10 Dimensions for adaptor pipe for DN200 to DN600 pipes (refer Figure 29 above) Pipe dimensions Internal d1 Pipe end (normal strength) d3
+0 -1
Pipe end (high strength) d3

+0 -1
Pipe body dM
Length (mm) l1
1
DN
mm 250 300 400 500 600 250 299 400 498 601
+3 -3 +5 -5 +6 -6
Average weight (kg/piece) 105 125 240 295 305
299 355 486 581 687
318 376 492 609 721
360 406 556 661 766
+0 -6 +0 -10 +0 -12
1,000 1,000 1,000 1,000 1,000
+7.5 -7.5 +9 -9
+0 -15 +0 -18
40
9931 ot 003
-fid retemaid edistuo ot gnidrocca sepyt hsuB .slaes M htiw enibmoc oT .secneref
2. M-seal and bush ring Another way of achieving the transition from a 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.
Left: M-seal with bush ring
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 installation methods. Type A One end sawn flat and the other with a steel coupling. Type B Both ends are sawn flat. Type C One end sawn flat and one spigot end.
190 Jacking pipe
12 length pipes are available to suit various applications and
Figure 31 M-seal and bush ring

M-seal
85 Standard vc pipe
An M-seal and bush ring is used to connect these three types together.
Sawn flat spigot Bush ring
Figure 32 Short length pipes

bk e
Type A dk d1 dM
Type B d1 dM
Type C d1 d2
l1
l1
l1
41
Corrugated Metal Pipe (CMP)

Top: CMP on-site manufacturing Bottom: CMP used in a culvert application
Humes Corrugated Metal Pipe (CMP) is a helically wound, lock seamed corrugated metal pipe and is available in 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

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. Humes design team ensure customers requirements are met. Large diameter culverts can be laid in live condition (running streams). Installed CMP has high load bearing capacity.
TRS profile
Figure 33 CMP profiles

TR profile
42
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) 300 375 450 600 750 900 1,050 1,200 1,350 1,500 1,650 1,800 1,950 2,100 2,250 2,400 2,550 2,700 2,850 3,000 Wall thickness (mm) 1.6 ++ ++ ++ ++ 40.5 34.0 29.0 25.5 22.5 20.5 18.5 16.5 * * * * * * * * 2.0 ++ ++ ++ ++ ++ 47.5 40.5 35.5 31.5 28.5 26.0 23.5 20.5 18.5 16.5 * * * * * 2.5 x x x ++ ++ ++ ++ 45.0 40.0 36.0 33.0 30.0 27.0 24.0 21.5 19.0 17.0 * * * 3.0 x x x x x x x ++ 49.0 44.5 40.0 37.0 34.0 30.0 27.0 24.5 22.0 19.5 17.0 15.5
Table 12 Maximum cover (m) for TRS profile Nominal internal diameter (mm) 900 1,050 1,200 1,350 1,500 1,650 1,800 1,950 2,100 2,250 2,400 2,550 2,700 2,850 3,000 3,300 3,600 3,900 4,200 4,500 4,800 5,100 Wall thickness (mm) 1.6 x x x x x x x 16.5 15.5 14.5 13.5 12.5 12.0 11.0 10.0 * * * * * * * 2.0 x x x x x x x 21.5 20.0 18.5 17.5 16.5 15.5 14.5 13.5 11.5 10.0 * * * * * 2.5 x x x x x x x 27.5 25.5 23.5 22.0 20.5 19.5 18.5 17.5 15.5 13.5 12.0 8.0 * * * 3.0 x x x x x x x 33.0 30.5 28.5 26.5 25.0 23.5 22.5 21.5 18.5 16.0 14.0 11.0 9.5 * * 3.5 x x x x x x x 38.5 36.0 33.5 31.5 29.5 28.0 26.5 25.0 22.0 19.5 17.0 14.5 12.5 10.5 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.
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 Middle: HumeDeck modular bridge system Bottom: Headwall
Tunnel and shaft Access, pipe jacking and ventilation shafts Segmental shafts One piece shafts Mine portals and reclaim tunnels Precast arches Box culverts Corrugated Metal Pipe (CMP) 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 info@humes.com.au
Head Office
18 Little Cribb St Milton QLD 4064 Ph: (07) 3364 2800 Fax: (07) 3364 2963
New South Wales

Canberra Ph: (02) 6285 5309 Fax: (02) 6285 5334 Grafton Ph: (02) 6644 7666
Melbourne Ph: (03) 9360 3888 Fax: (03) 9360 3887
Tasmania
Launceston Ph: (03) 6335 6300 Fax: (03) 6335 6330
Queensland
Brisbane/Gold Coast Ph: (07) 3866 7100 Fax: (07) 3866 7101 Bundaberg Ph: (07) 4152 2644 Fax: (07) 4152 5847 Rockhampton Ph: (07) 4924 7900 Fax: (07) 4924 7901 Sunshine Coast Ph: (07) 5472 9700 Fax: (07) 5472 9711 Toowoomba Ph: (07) 4694 1420 Fax: (07) 4634 3874 Townsville Ph: (07) 4758 6000 Fax: (07) 4758 6001
Fax: (02) 6644 7313 Kempsey Ph: (02) 6562 6755 Fax: (02) 6562 4235 Lismore Ph: (02) 6621 3684 Fax: (02) 6622 1342 Newcastle Ph: (02) 4032 6800 Fax: (02) 4032 6822
South Australia
Adelaide Ph: (08) 8168 4544 Fax: (08) 8168 4549
Western Australia
Gnangara
Sydney Ph: (02) 9832 5555 Fax: (02) 9625 5200
Ph: (08) 9302 8000 Fax: (08) 9309 1625 Perth
Tamworth Ph: (02) 6763 7300 Fax: (02) 6763 7301
Ph: (08) 9351 6999 Fax: (08) 9351 6977
Northern Territory Victoria

Darwin Echuca Ph: (03) 5480 2371 Fax: (03) 5482 3090 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 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

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