Pipe Jacking

An introduction to pipe jacking prepared by the

Pipe Jacking Association

Steven Cowell - Introduction

J. Murphy & Sons Ltd.

Estimating Manager - Tunnelling

26 years in the tunnelling industry

Design, project delivery, planning & estimating roles

Pipe Jacking Experience







Hand excavation, road-header & back-hoe shields

Open, EPB & slurry TBMs
Dewatering, ground treatment & compressed air
Diameters from 1.0 to 2.5m
Drive lengths to in excess of 500m

Agenda

Introduction to pipe jacking and micro-tunnelling

Excavation methods and machine technology

Drive lengths and diameters

Jacking loads

Jacking pipe materials

Guidance and controls

Site investigation and ground conditions

Comparison with open trench and segmental tunnels H&S, environmental and
technical benefits

PJA research

Some Murphy pipe jacking examples

What Is Pipe-jacking?

The PJA definition

Pipe jacking is a technique for installing underground pipelines, ducts

and culverts. Powerful hydraulic jacks are used to push specially designed
pipes through the ground behind a shield at the same time as excavation is
taking place with the shield.

Pipe

diameters 0.45m to 2.4m commonly available in the UK

Larger

The

diameters regularly used overseas

term micro-tunnelling is used for the diameters 0.45m to

1m

Jacks in excess of 1km in length undertaken in the UK

Typical Construction Sequence

Sink launch shaft, using

whichever method is
appropriate to the ground
conditions.

Sink reception shaft, using

whichever method is
appropriate to the ground
conditions.

Install jacking rig

Set up system, control

container, separation plant
and pumps.

Launch TBM and

commence drive.

Complete drive and recover

TBM from reception shaft.

Common Applications
Sewerage and potable water construction

Gas and water utilities

Industrial pipelines (e.g. oil, chemical etc)

Electricity and telecoms utilities

Pedestrian subways

Excavation Methods & Machine Technology

Then - The good (bad!) old days:

Manual excavation & loading

Common up to early1990s

Health & safety issues
 HAVS
 Manual

handling
 Occupational health

Now - Very limited manual excavation

Max. drive length 100m at >1.2m i.d.

Max. 2 drives or 150m in one project

Must seek HSE guidance

Strict controls put in place

Excavation Methods & Machine Technology

Machines are available for pipe jacking in the majority of ground conditions

Backhoe Excavator

Road-header

Earth Pressure Balancing TBM

Open Face TBM

Slurry TBM

Machine Technology
Backhoe Excavator

For competent and stable ground conditions

E.g. clay, dry / stable sands

Suitable above water table / in dry ground

However, can be used in conjunction with

dewatering

Machine Technology

Open face cutter booms (road-header)

For strong cohesive soils and weak to

moderately strong rocks

Operated above water table

However, can be used in conjunction with

dewatering

Machine Technology
Tunnel Boring Machines (TBM) - Open face

For stable face conditions, including competent rock.

Various cutting heads available to suit a broad range

of ground conditions

Suitable above water table / in dry ground

Can be used in conjunction with dewatering

Spoil removed via a conveyor belt or auger

Machine Technology
Earth Pressure Balance (EPM) TBM

For less competent ground conditions

Can be used in saturated ground

Most suitable for cohesive soils

E.g. clays, silts, etc.

Excavation controlled by continuous

flight auger

Additives for face / spoil conditioning

Machine Technology
Slurry TBM

For less competent ground conditions

Can be used in saturated ground with high pressure

Most suitable in granular soils

E.g. sands, gravels, cobbles

Excavation controlled by slurry system

Microtunnelling Systems

Fully guided machines

Controlled from surface

1m i.d. and below

Non man entry

Similar to larger diameter

pipe jacking machines

Two options:

Pressurised slurry

Screw auger

Drive Lengths and Diameters - HSE Recommendations

Jacking Loads - Capacity

Ultimate jacking load dependent upon:

Pipe load capacity

Jacking wall / restraint capacity
Diameter, length & weight of pipes
Ground & groundwater conditions
Excavation method & control
Cycle times / working patterns
Alignment control
Maintaining annulus
Lubrication
Main jacking station capacity
Intermediate jacking stations (number /
capacity)

Jacking Loads - Reduction & Control

Good practice should include:

Correct choice of excavation method

 Open,

EPB, slurry

Control of groundwater
 Dewatering,

Good alignment control & correction

 1

= 50 to 90% reduction in pipe capacity

Maintenance of cut annulus

 Cut

diameter, TBM / shield over-cut

Good lubrication
 Injection

ground treatment

points, Bentonite, water & polymers

Correct choice of intermediate jacking stations

 Number

required, capacity & position

Jacking Pipe Materials

Concrete jacking pipes

BS EN 1916

Clay pipes:

BS EN 296-7 & BS EN 12899: 2000

Steel pipes

GRP pipes

Guidance & Control

Continuous & real-time

Normally laser guidance

Maintains accuracy

Line, level & attitude

Permits remote operation

Smart targets

Camera targets

Giro compass (curves etc.)

Site Investigation

Ground Conditions

Comparison with Open Trench

Comparison with Open Trench

Pipe jacking

Comparison with Open Trench / Segmental Tunnelling

Technical
Comparison with Open Trench


Minimal surface disruption and
reinstatement


Fewer utility diversions
Comparison with Segmental Tunnelling
Inherent strength of pipeline




Smooth internal finish


No secondary lining


Less joints


Watertight


Control of settlement

Comparison with Open Trench / Segmental Tunnelling

Health & Safety
Comparison with Open Trench

Utility disruption minimised

Public interface reduced

Comparison with Segmental Tunnelling

Reduced labour requirement

Reduced installation time

Reduced manual handling

Non man entry where possible

Comparison with Open Trench

Environmental

Avoid damage to services

Reduced disruption

Maintains highway integrity

Carbon footprint

90% fewer vehicle movements

Less spoil

Less quarried material

Carbon Footprint & PJA Calculator

The PJA has worked with the North American Society of Trenchless
Technology (NASTTBC) which is at an advanced stage of developing a carbon
calculator for trenchless technology

The carbon cost of traffic disruption has been studied by the Centre for the
Advancement of Trenchless Technologies (CATT) and at the Department of
Civil Engineering at the University of Waterloo, Ontario

Subsequently NASTTBC developed a carbon calculator tool through the

University of British Columbia

A combination of the reduction of traffic and trenchless construction outputs

resulted in carbon reductions in excess of 90% compared to open trench
construction.

The PJA has developed a UK tailored product and incorporated TRL/Halcrow

traffic data developed for NRSWA impact studies carried out for UKWIR

The Carbon Calculator tool is available from the PJA website

90% Reduction in Carbon Emissions

When compared to open trench

excavation pipe jacking can
reduce construction related CO2
emissions by 90%.

PJA & University Research

Two decades of research

Oxford, Cambridge and Newcastle Universities

involved

Supported by water companies and the EPSRC

Research both laboratory and site based

Research Projects

Laboratory testing of model jacked pipes

Field testing of performance of pipes

Finite element analysis of concrete jacking pipes

Full scale testing of concrete pipes

Soil conditioning and lubrication materials

Field testing of soil conditioning and lubrication methods

Slurry management (spoil disposal medium)

Guide to Best Practice

Soils investigation
Excavation systems
Temporary and permanent works
Jacking lengths and friction forces
Best installation practice
Worked examples and checklists

Additional Applications
Box Sections

Subways

Roadways

Other uses

jacked arches

bridge slide
foundations

Pipe-jacking Examples

Preston 7 UIDs - Direct Pipe Installation

Client: United Utilities

Ground Condition: Silts, sands, clays, cobbles

Dimensions of Drive: 2 drives x 1.5m i.d. x 865m

Machine: Herrenknecht slurry TBM

A new technique - used only14 times worldwide

First use in the UK

The longest drive to date worldwide

1st drive currently 80% complete

Pipe-jacking Examples

Preston 7 UIDs - City Works

Client: United Utilities

Ground Condition: Sandstone

Pipe-jacking: 5 jacks x 1.5m i.d. 550m total

Machine: Open face rock TBM

Challenges:Restricted
Abrasive

urban location

rock conditions

Pipe-jacking Examples

Lower Lea Valley Cable Tunnels

Client: Olympic Delivery Authority

Ground Condition: Sands / gravels and

beneath a high water table

Pipe-jacking: 2.52m i.d. x 70m length

Machine: Iseki slurry machine

Challenges:- Highly permeable sands and

gravels with water close to ground level

Pipe-jacking Examples

Taplow

Ground Condition: Chalk with high

permeabilities

Pipe-jacking: 1.5m i.d. x 140m

Machine: Iseki slurry machine

In Summary . .

Engineering integrity
Low capital costs
Low maintenance
Cost-effective
Safe installation
Environmental benefits
Extensively used worldwide
0.45m to 3m diameters
Long drive lengths
Good engineering performance

Thank you for listening.

Any questions?

Pipe Jacking Association

10 Greycoat Place, London SW1P 1SB
Tel: 0845 070 5201 Fax: 0845 070 5202
Email: secretary@pipejacking.org
Website: www.pipejacking.org