Copyright © Pipe Jacking Association 1995 All rights reserved. No part ofthis Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopy, recording or otherwise, without the prior permission of the publisher Whilst the Association does its best to ensure that any advice, recommendation or information it may give is accurate, no lability or responsibilty of any kind (including labilty for negligence) Is accepted by the Association, its servants or agents, in this respect. Published by the Pipe Jacking Association and produced by Marshall Robinson Roe. Price £35 ISBN 0 9525982 05 First Edition June 1995Acknowledgements he Pipe Jacking Association would like to extend its thanks {0 the following for their assistance in the compilation and the provision of specialist technical input: © MHough BSc CEng FICE, Dr G WE Milligan - Department of Engineering Science, Oxtord University, Members of the Pipe Jacking Association Technical Committee, and the following water companies, who as members of the Oxtord Research Project, have made a valuable contribution. S Da North NORTHUMBRIAN West SMeahrres: “WB” Wateripe Jacking was trst introduced into the Unites Kingdom in the early sixties and was used as an allernative tunnelling method to srnall segmental tunnels and timber headings, for providing short crossings under obstacles such as roads, raihways, rivers and canals Te technique developed and it ‘became practical to use the method for longer tunnel drives, and so pipe Jacking found a market in the sewer and surface water sectors. In 1973, six contractors who were using the technique formed the Pipe Jacking Association (PUA), o promote and ‘market the method through a Code of Conduct and Good Practice Later the Pipe Jacking Association in conjunction with the Concrete Pipe Association (CPA), produced a Design and Specication Bulletin on Jacking Concrete Pipes, and this became an adopted document for most end users. Other publications followed, including a design guide, case histones and newsletters, and the Association embarked on a series of leclufes and seminars to educate utlty companies and other clients, on the art anc benefits of this new tunnelling system, Preface During these developing years the PJA has attracted new members, including some of the concrete pipe manufacturers and tunnel machine suppliers, and has now established itself as a leading word authority on the technique. In 1983, the Construction Industry Research and Information ‘Association (CIRIA) were co-opted, to promote and support a basic research programme. They ‘embarked on a state of the art review (CIRIA Technical Note 112) and from this produced a list of research requirements for detailed study. ‘These may be summarised as: (@ Friction loads in diferent ground conditions @ Characterstics of pipe joints and joint packing materials, 1 Erfects of cyclic loading on pipes @ Effects of lubricants in rectucing friction © Development of a site investigation test to predict friction forces Under the initiative of the Pipe Jacking Association, support nas ‘been obtained for four stages of The fist stage, backed by the Science and Engineering Research Council (SERC), involved a desk top sludy and laboratory testing of ‘model concrete pipes, carred out al Oxtord University The second and third stages, have involved full scale on site testing and instrumentation, and have. been supported by five major water companies - Northumbrian, Nosth West, Sevem Trent, Thames and Yorkshire. ‘A fourth stage is using tinite element methods to model pipes and joints ina search for improved designs. The research projects have been an outstanding example of co- operation betwaen clients and designers, contractors and pipe suppliers, research organisations, and academia ‘As a direct outcome of the research programmes this Guide to Best Practice for the Installation of Pipe Jacks and Microtunnels ha: been compiled to provide a code ‘hich includes both past ant ‘current knowledge of the Art and Science of Pipejacking1.0 introduction 2.0 Objectives of this guide 2.0 Parameters to be considered to produce the best scheme design 3:1 Sol investigation a ion 3.2 Suitably jack 35 Working shait design, trust walls, 3.4 Drive lengths, jacking and iriction Toads. intermedia stations, lubrication interpretation bishment 3.6 Pips jacking pipes 37 Ground movement 4.0 Good installation practice _ ~__ 4.1 Siaering control - 42 Loading control 43 Record controlipe Jacking, gencially referred to in the small diameters less than 900 man as mierotunneliing, is a technique for installing underground pipelines. ducts and culverts. Powerful hydraulic jacks are used fo push specially designed pipes through the ground behind a shiold from a thrust pit containing a thrust wall To establish the bast practice for the installation of good pipe jacks and microtunnels itis essential te Understand all the parts that must be strung together to achieve success. These include good soi knowledge, jacking shatt design. pipe design. pipe jack shiakd design, Nydraulc considerations, and laser engineering. but each aspect, whether it may seam very significant or of minor importance, must be considered for every scheme in order thal success may be guarantees. A successful pipe jack is ike a chain which is as strong as the weakest fink itis ike (he launcting of a salallio where allthe parte have bean properly researched and Gesigned to create a finished project which is well engineered and, in pipe jacking tems, will Provide the best flastle, structural, watertight pipeline turroliing method available in the market — Good anchorage 2 “4 XX __ Ah! forget the link = | Cor the interjack maybe { 2\ —— Did we check the load 72.0 ipe Jacking has been with us for over 35 years bul is only iow ‘coming of age with the skill of pipe and tunnel machinery manufacturers, research and promotion by the Pipe Jacking Association. some innovative scheme designs. anc progressive pive jacking contractors. ‘Superiicial glacial deposits in the UK, through which many pipeines require to be positioned, have created the need for a range of sophisticated equipment which has been utlised by the UK tunnelling industry, and has generated probably the most experienced pipe jackers in the wor'd. ‘As prefaced, in recent years both desk and field research have been carries out at Oxtord University with the involvement of the PJA, CIRIA, SERC (now EPSRC), and five water companies. ‘Taking all that is known to date, the objectives of this guide are to set out in simple readable and illustrated text the essential elements that are necessary for the design, specilication and installation of pipes by the pipe Jacking method, ‘The quide then takes the reader through the problem areas which can adversely affect a pipe jack, provides a check Ist, and summarises associated matters such as contractual considerations, safety, training, and current regulalions and standards. which are all good practice for the pioe jacking method. itis designed for an audience of promoters, clients, consultants contractors, estimators, planners, machine manulacturers, material suppliers and any other parties with an interest in the pipe jack construction process. Be guided that members of the Pipe Jacking Association are always available to advise on any aspect of the technique, and other publications relerred to within this document should be used in conjunction wath this guide. Itis the policy of the PUA to continue a planned programme otf further research and practical analysis and to uodate information as itis gained 2.1 2.1 How to use this guide Each Section from 3.0 to 7.0 {pages 8 to 41) details the essential information required to produce a 900d pipe jacking or microtunneliing scheme design and installation. The guide is designed to follow a logical sequence and in some sections makes cross relerence to cotter publications and guides. Headings such as: Advise(d) 15 key points. However, ail information is important Section 8.0: Apgendix, relates to technical formulae, graphs and calculation data. Section 9.0: Worked examples, provides the reader with a guide to the use of technical data for !wo sample pipejacks. Section 10.0: Relerences, refers 10 publications, research data, codes of practice and other appropriate information. Section 11.0: provides 4 Glossary of terms used in this guide.4 Soil investigation and interpretation Belore ary practical decisions can be nade relating 10 @ scheme design tor pipe jacking, itis essential that an sppropdate soit investigation and interpretative repor is available for both the designer and installer. Ths inlormation is required to evaluate the basic selection of the type of tunnel excavation method Saction 3.2 the working shafi(s) and thrust wall construction Section 3.8 Ine length and strengti of the pipeack Section 3.4 any requirement for ground stabilty control Section 3.7 The PJA publication “An Introduction to Pipe Jacking and Microtunneling Design’, Part 3, covers the characteristics of soils likely 1o be encountered and the minimum information required for a proper interpretation to be undertaken Interpretation of sod information is not @ precise science and experience vinether it be practical Or specialist, should be sought to give the best possible evaluation Otten forgotten, but of great value, 1s noting any expenienoe of the ground from previous or current work in the area Also special problems such as the presence ol fiammable gases, de ‘oxygenaied air, or contaminated ground should be investigated, as these nay wluence or dictate the choice of tunnelling method. Below are examples of some of the basic problems which may anse and solutions 10 consider for controling varying ground, @ The gracing of non-cohesive sols will quide toward the compaction or looseness of the soil and the presence of fines, which may cause inetabilty Solution Dewatering ‘Stapiisation Face suppont Tunnel Boring Machine @ Sune conesine sods can become Unstable whien the presence of water alters ther plastiotty oF creales pressure in fissures Solution —_ Fave suppot Tumel Boring Machinesol stresses @ Over consolidated clays can create high {nction forces as Solution Lubrication are released around the pipe during jacking A. Intarjack stations " @ Mixed soils or material used for filing (emibankments etc) should be examined by trial pits to assess the best pipe jacking method a Solution Consult a soil specialist or take advice from the PUA. @ The presence of rock or boulders may disrupt the excavation method The advice of specialist shield manufacturers should be sought forth conditions. Solution Ask a machine manufacturer and take advice from the PJA ‘@ Some soils which are normally stable may be rendered unstable in the > presence of water. The instability is caused by water movement, through or with the soil, due to the differential head created by jacking a pipe below the a water table. oe Solution Dewatering Wm Stabiistion ceniy/sit Tantei Boring Machine => TR paar Le Where the presence of excessive water is expected, evidence ol labie(s), artesian head(s), should be noted along with the results of permeabiliy and/or purnping tests. Tha presence of, and dealing with water, is probably the most cammon anc contentious contractual element of any tunnelling method and pipe jacking, Js no exception. Many factors such as location of shafts, interference with surface structures, traffic requirements, and environmental noise regulations, can intertere or limit the best construction method {tis essential that both the designer and installer work together to find a solution thal is both cost effective, technically viable, environmentally friencly ater No soil information, = Scheme risk3.1 continued Be guided ‘Study Part 3 of “An Introduction 10 Pipe Jacking and Microtunnelling Design’ The diagram opposne ilustrates the minimum information required Be guided GAGUND TREATMENT AND FACE SUPPORT METHODS FOR VARYING Stouno contro ‘Study Part 1 of An Iniroduction 16 Pipe Jacking and Microtunnelling Design” and cross reference it with Section 3.2 and Section 37 of this guide3.2 Suitability and selection of pipe jacking excavation methods The stability of an excavated bore is o! consiierable unportance in pipe jacking Large ground movernents above the pipeline may cause damage to surtace structures oF services. Ground collapse on to the pipeline will greatly crease the resistance 10 jacking and may lead to high jacking loads Face excavation collapse may endanger the pipe jack miners or excavation machinery. As slated in Section 3.1 of this guide, ground conditions must be caretully assessed [0 anticipate possible face instabilities particularly in cohesionless soils below the water table, solt clays. sits and mixed soils, ‘Where any possibilty of collapse exists, consideration should be given 10 the use of ground water lowering or removal techniques, grouting or ‘chemical stabilisation of the soil, or the use of earth-pressure balance or slury suppor tunnelling machines The fava stability in cohesive soils may be assessed by reterence Wu Figure 1n the Appendix to this guide. In cohesive soils the face pressure requires 10 be Contolled to ensure that neither excessive settlement nor heave occur. is recommended thal « factor of safely of 1.5 10 2.0 on soil strength be used in soft clays to limit settlement or heave Stabilly of cohesive sols around a pipeline 1s a function of the undrained strength of the soll and in cohesioniess soils depends on the angle of {ction of the so Tunnel stability may be assessed trom Figures 2 and 3 m the Appendix to this guide. Excavatun forthe installaton of jacking pipes i unertaken ether by hans OF machine within a stueld, or by a tunnel boang machine Mustiated are the lypes of shield currently m use. Tue veg RAF Tey oe Wy i free ond sot tx baarakig out or var premeure I : | | | 5 \ Hand Shield. 0 open fave Backacter A open face she wit a mechenical backactat Cutter Boom: Aa open face shiek wth a tater boom oF roa header ‘Tunnel Boring Machine (T8M) A shild with a rotating cuting head Earth Pressure Balance Machine (EPEM) "Atul lose funnel Boring machine wth a ‘calanced screw auger to conto the face pressure A luly quded remote corto acti3.2 continued The PJA “An Introduction to Pipe Jacking and Microtunnelling Design” ilustrates in Part 4, the types of excavation methods available and also tables the selection of pipe jacking shields as related to: Excavation ype of shed Pipeline internal diameter ange Length range upto? Face support inbuilt or addtional? Remarks —_ciher relevant matters Itis recommended that this section is studied caretully anc used 10 seleet the best excavation and face suppor method for the ‘ground conditions applicable to any scheme, There are many types and manutacturers of pipe jacking shields and TBMs, and each type will have its own design anc! performance characteristics, Alter selection of an excavation, system the designe:/installer should contact the equipment manufacturer to obtain precise ‘nlornation specitic to the choserr equipment, 19 ascertain the suitability of \ts operational capacity to handle the ground conditions. ‘Summarised here is a guide 10 ‘some of the efleria to 100k for in assessing the suitabiliy of the equipment for good installation Hand Shield Anand shield must be equipped with at least four steering jacks spaced around the lead pipe. The shield should be of a diameter siighily greater than the outside pipe diameter to allow it to be steered and provide an annulus for lubrication The aspect ratio of diameter to length of a shield can be critical to its steering ability. Advice from the shield manufacturers should be sought on this matter. In Gir ground conditions the excavation may proceed with slight overcut to the shield circumference. Alternatively tne shield can be used to tim the under excavated face. In loose ground conditions Consideration should be given to the provision of a protective hood andor ground breasting boards or sand tables J tabocans \A Hoos Breasted ‘oad ace positions Backacter: Cutter Boom Backacter or cutter boom shields are essentially open face shields with a mechanical means of excavation The backacter type is suitable in semi-stable to stable sols up 10 strong cohesion values. The cutter boom is more suitable in higher strength soils, maris and some rock types. ‘When choosing a machine be guided to: @ The required power of the mechanical excavation device to ‘excavate the sol @ Facilities to contain soft material released from the face and water intrusion © Steering control facilities @ Independent shielo thrust jacks @A suitable spoil disposal arrangementTunnel Boring Machine (TBM) Earth Pressure Balance Machine (EPBM) ‘Tunnel bonng machines come in These shields use the excavaied many guises and are probably the soil lo provide a pressure to contain most common mechanical face the ground face toad ‘excavation method for pipe jacking ‘The face is supported by excavated varying soils ‘material held under pressure The face excavation 1s supported behind a cuter head in front of whe bya number ol techniques, anda forward bulkhead. Pressure is considerable variety of machines controlled by the rate at passage of aie available in the market place for excavated material through a tunnelling thwough diferent ground balanced serew auger or valves on conditions, the screw convoyor, Slurry caches use the pressure Of the sturry to balance the ground water pressure at the face, and the excavated material is transported fom the face in the shanty Air pressurised machines balance the ground water pressure by sompressed aur in the excavation, chamber. In choosing & suitable machine be guided 0 the fallovang facil @ Cunt: head tll !ace suppon or cutter ans only @ Adjustable cutter face doors Slurry ot water suppon eh @ Compressed at support chamber (@ Fock or hard ground outer adaption (@ Rock or boulder crushing feciities (@ Mechanical or slutty visposai method @ Steering contol @ inciependent shits thrust jacks @ Yan-enty and maintenance Typeadncrotumeting set up taciities 10 the excavation lace Microtunnelling ‘Microtunnels are normally excavated with a TBM auger or slurry type machine adapted for sinaller diameters and remotely conbotied They are equipped with active target systems or close circuit television, for line and level control The main be guided ponts ae @ The type of excavation head required lor the soil conditions, beating int mind that a change of the excavation head below 101d, ie not normaly feasible @ An assessment of the risk of ‘obstructions OF onerous ground conions which could abort pipe drive, and any contingency arrangements © Sutabilty of the method to cope with high water table pressures @ Boulder oF 100k cutting apatites © Length of mirotunnet equrea and whether an intorjack facility 15 practeable3.3 3.3 Working shaft design, thrust walls, and conversion to manholes The warking shalt requirements for pipe jacking are dependent on the following factors: Be Guided and avoid Problems @ lis sultabilty to accomodate Ue shiek! anc jacking equipment selected, Prowsion for an adequate thrust wall and pape jack eye A tacility tor removing spoil, and space for lowering and joining the yacking pipes and/or Interiack stations, 11 the shall is reception only, space 10 remove Ihe shield via a pipe Jack eye Problems — Scheie delay Cost implications, Lostehield © Lis sutabany 10 support the: (ese and water iIrUSION ot the subsoils. Problems iditlons, @ The pracheani STialt together vath the the worms mstallation plant required in labo sito Brea (IneANCing consiseraLon ol overhead restrictions). The presence of adjacent structures, exsting services, wallw: considerabons vibralion problems, emironmenial and noise linitations Problems — Salety of utilues Cost implications Public safely and relations Insurance risk Working shafts will requte the mooxporation of pipeyack eyes wract in simple? terms are a means of allowing the sale ontry and exit of the shield. The eve may be a simple hole through the shaft in state ground conditons, but will ‘require special design in loose ground 1o prevent ioBs of sew around the shield at the shaft entry and exit postions, Stun TAMs atso require” acioquate entry and exit seals In igh water table conditions, @ nurnber of techniques are availatae including specially designed pressure collass, andor de- watering, gouting ‘or grout replacement methods, oF Ireezing ol the surrounding Seis. adverse water conditions the shield can be enteted and retrieved, usm compressed ar methods applied 10 the shaltsWorking shalt co sclion methods used wath pipeyacking miclude. ‘Segmental li 98 Precast or cast insitu caissor Sheet piling or secs Shallow trench sheeted or timber supported excavation Battered tion Ground anchorages The PUA “As Introduction to Pipe Jacking and Microtunneling Design” tables In Part 4, a guide to practice for selection of shafts in dry and wet ground conditions as related to: Type Tie ot methoa Size & Shape Tiitations — — Depth Range up to or unlimited Ground Treatment Whether required or additional Remarks Other relevant matters Its recommended that this section is studied carefully and used to ‘select the best shail size and construction metnod for supporting the ground applicable to a scheme, taking into account the other working shal criteria a3 necessary Il is essential that whichever working shalt construction method s selecteo, it must be properly designed to withstand the stresses which will be imposed by the sub-soil and water pressures, together with the thrust wail loads and local stress concentrations caused by construction of entry and exil eyes for the excavation shield. Some practical installation alters are recommended below. ‘Segmental linings Care should be takes! (@ provide good backgroutin over the area used to construct the thrust wall Where linings are to be removed for entry and exit ot the excavation shield a frame / pipejack eye must be designed to transter the stresses from the discontinuous segments 10 the hnungs especially3.3 continued a we YY anita od J] a Precast or cast insitu caissons Care must be taken not to lose ground support due 10 formation heave during the sinking of caissons, The effect of friction lubrication must be considered in relation to the thrust wall design. This choice of construction is Ikely to be selected for soft, water ladon, ground conditions and therefore caretul consideration is required for break out and break in, Sheet piling or secant piling ‘Sheet piling along with segmental fnings are probably the most used methods for constructing working shafts. Shee! piled shafts must be properly designed to incorporate secure walings and struts, positioned so as not to impede the jacking operations Sheets including corner piles must be irkerlacked to prevent water ingress, and loss of ground to the detriment and stabily of the shall, thrust wall and pipe jack eye. Piling should have a designed toe-in cut off below formation level dependent on soil conditions, Shallow trench sheeted or timber supported excavation Working shatts of this construction are more usual for short or shallow pipejacks. There is likely to be a restriction on the practicat thrust wall loads achievable, anc such construction is probably oniy suitable in dry stable ground coneitions. Good sate trenching practice must apply to supporting the excavation Battered excavation Again such construction is applicable to shallow short pipejacks. The batter must 5e designed against sip conditions, and must comply with the recommended safety regulations. Ground anchorages This is a requirement for jacking pipes at ground level or just below, ideal for jacking under a road or rail embanarnent The anchorage could take the form of propped cantilever piles of a ground ‘anchor arrangement, and wil be purpose designed ‘or each scheme.Thrust walls nave for many years, been designed empirically by taking a conservative ground passive resistance stress, and determining the area of the thrust wall against a calculated maximum jacking load. In many cases these empirical designs are adequate and exoerienced pipe jacking contractors have designs that have been proved effective in practice {tis not normally necessary 10 reinforce a concrete wall except sometimes for punching shear reinlorcoment, Bending moment loads should be avoided by having an adequate oack spreader between the thrust wall and the thrust jacks to distribute the toad In many cases, for example with sogmentaly lined shafts, a purpose made steel thrust wall can be designed to spread the load over the segments, and be re-usable for many drive lengths (see sketch page 14), Nis advised that standard structural design practice is used for each specific scheme as the design parameters of depth, soil strata, and thrust load, will be unique to each project, It should be recognised that a thrust wal is a temporary structure which is likely to be aborted after use Therefore itis acceptable to use lower factors of safety in design calculations than would be acceptable tor permanent works. However, failure of a thrust wall can have far reaching consequences, and if the failure is one of internal failure of soil friction or cohesion, it can be very coslly to re-establish Such costs could also include overcoming friction build up to restart the pioe jack (see Section 3.4) Where a pipejack is to continue trom a shall lo which a completed pipeline has been jacked, then consideration must be given to protecting the pipes aready installed. Measures should also be taken 0 engure that the completed pipeline is not pushed backwards i itis incorporated in a thrust wall Manhole requirements will vary with each scheme design, but practical and cost considerations should be taken into account when assessing the requirement(s) of the working shaft(s) and how this might be convertad to a manholes) ‘Segmentally ined shafts are ideal for conversion, but in some cases may be too large as manholes. In such cases consideration may be given to using a smaller shalt and enlarging the bottom to create a working area for the pipe jacking rig. Such designs may be cost effective on deep pipe jacking schemes, Precast and cast insitu caisson lend themselves to an all emoracing design for working shaft and final manhole or pumping chamber. Sheet piled shatts are ideal for incorporation of a chamber type manhole which can be backtiled and the piles removed, or not as necessary, after due consideration of ground pressures and/or costs. Other working shalts are easily converted, but in all cases itis advised that early discussion is held with the promoter or designe: to ‘ensure that both the scheme design and the installation requirements are: tbeing met for both good practice and cost evaluation. Fentoe zs Sangths, jacking and friction loads, intermediate jacking stations, lubrication Theoretically, there is no limit to the drive length of a pipe jac providing all the elements that make up a pipe jack have no imitations, In practice a pipe fack will be limited by considerations such as time restrictions, cost evaluations and safely factors The following tabulates the elements which make up a pipe jack and detail the ‘imitations: Element Limitation to drive length Working Sha No limitation other than thrust wall load, wich can be limited by use of interjack stations Jacking Shield Hand shield Physical limitation of time for removal ol spoil, and ulld up of friction ‘oad Machine shielo Cost limitations 10 the distance et spoil removal from the face to the shall. Auxiliary pumping required for slury machines. Limited by the need to celurbish the face cutters in abrasive soils Jacking Pipes No practical imitation, providing interjack stations are designed to limit the jacking loads Interjack stations —_Time/cost Imitation after several interjacks have been employed, due to the speed of the shield against the lime required 10 operate the interjacks Spoil removal ‘An important iitation on practical drive lengths Both mechanical and pumping disposal will iit the practical and economic production Lubrication’ ‘Some practical injection limitations for long drive lengins Friction loads Dependent on the arching behaviour (or stand up characteristics) of the soil Slow build up with time will determine the ultimate drive length Tolerance checking Sophisticated control systems will be required for Jona drives It may be seen from the above table there are some practical imitations to long drive pipe jacking, and these may be summarised as time restrictions affecting friction limits, and cost restricions due to practical production being controlled by spoil disposal limitations.Taking suc factors into account, the practical and economic lengths with current technology are up 10 800 metves for pipes in the 1200rm to 2500mm diameter range, although in some cases longer lengths could be considered, Large diarneter pipe jacks have bbeen driven up to 1500 metres, and ‘over It 18 consicered that in the market place of sewer and water conduits, where long pipe jacking finds ts major use, thal most schemes will require 10 be designed with working shalts at 500 metres oF less Microtunnelling is restnicted by the Jacking load limit of the pipes, the practicability of introducing interjact slalions, and the constraints of guidance systems in the smaller diameters Drives of 180 metres'are common place and greater lengths are achievable, Where practicable iis recommended that to achieve ‘good drive lengths and good pipe jacking, the maximum space facilities are granted for the working halts, and the shalls are designed of sufficient size to easily accommodate the main elements of a pipe jack ie. the shield, the Jacking rig and pipes, thrust wall {and pipe jack eyes, spoil removal plant, guidance systems and all ‘other ancillary equipment Tight working concitions can be accommodated using special plant, and short pipes, but it should be noted that logistical and access difficulties may lead to inefficient working practices, resulling in cost escalation The Jacking load required to install a pipe jack is derived from the following; @ Face load 10 advance the shiek @ Self weight of the jacking pipes in stable ground @ Friction around! the jacking pipe: due to ground closure or unstable sols @ Misalignment or tne delay during jacking Ihe shield load is normally a ‘constant whilst the self weight of the pipes is a linear loadidistance increase. The ground soil friction may vary both linearly or exponentially, depending on the arching behaviour of the soil, the accuracy of the pipejack. and the time andor delay. Misalignment anc time dolays are discussed elsewhere, For many years the PJA has given as a guide, frictional forces in the range af 0.5 10 2.5 tonnes pe square metre of the external circumferential area of the pipes. depending on sali conditions3.4 continued Forces due to Face load will ve relativaly low in cohesive ground and related to the excavation and ltimming of the shielc Hand mining slightly larger than the shield, as against use of shielo liming, can vary a tace load from 10 t0 100 tonnes For a machine diwve the average face pressure, including slurry pressure, shielo tamming and ‘excavation, can be calculated using the appropriate formulae in tne Appendix (Section 8) and Worked Examples Scheme 8 (Section 9) Forces due to tne Selt weight of the pipes in a slable bore ave a tunction of the weight of the pipes(W) to the local interface ‘riction coefficient (6). A factor ot % should be added to vover minor misalige vent F— 1 25Witand In solt clay a more appropiate model is that of Haslem (1986) as « Figure 4 of the Appendix to this guide. When the ground cioses onto a pipeline, the resistance will increase considerably compared to that of a stable bore Even when the excavated tunnel is stable, the ground may close onto the pipe due to “elastic” unioading Of the grounig around the tunnel ‘Tne reductions in vertical and horizontal diameter of the opening may be estiriated from the elastic analysis as given in Figure 5 of the Appendix to this guide. If these ‘eductions exceed tie iritiat overbreak, contact between soil anu pipes will occur, rackal stresses will develop, and resistance to jacking stat to increase In non-stable bores, the Ground ‘soil friction created is a function of the internal friction of the soil and its interaction wilh the pipe. ‘Arvo for loading in conesiontess soll may be found in Figure 6 ofthe ‘Appencix to this guide. From the Oxlord research, measured friction forces during pipe jacking tended to be slightly below past empiical experience, and compared wel wih theoretical analysis. However, readers should beware that pipeline construction does not ‘always occur in homogeneous soi conditions. Also soils do not al behave as predicted, Both theoretical and practical skits should be applied (0 provide youd and sate working conditions Misalignment must inevitably induce contact stresses betwoon the pipe and the ground. Examples of the effect of misalignment may be obtained from the Oxford research data {3 well known thal Time delays will create restart jacking loads higher than those needed to maintain steady motion, Research data has confirmed that such increases can oceur during short stoppages and may increase by 25% within an hour, and up 10 75%. ‘twenty four hoursTh intermediate jacking station is used to limit the pressures applied to the pipes and the thrust wall by making use of the friction forces created by the following ploes. The interjack is entered at any position determined by the overall frictional resistance and operating load available trom the thrust wall The interjack itself consists of a steel cylinder which matches the outside diameter of the jacking pipe and is filed, either as a tolerance fit to the leading interjack pipe, or some cases comes factory filed from the pipe manufacturer It must to be designes to cater for ground, hydrostatic and thrust load conditions cbeicant used rad press ised Intermediate Jacking Station (or lnoiack) A trailing interjack pipe, recessed to slide into the interjack shield, is positioned behind hydraulic jacks. These are used 10 activate the station to move the forward train of pipes independent of the trailing pipes. using the friction resistance of the trailing pipes to reduce the load on the main thrust wall al length ‘a> mairer tata Ine bed «2 260 tonnes. B9 ‘anh Nola seat the wen, tH ope oad fee ‘A nuiniber of meyack stabons may be employed for long jacking distances, and it is usual to design the jacking capacity of the interiack station to have reserve in the event of jacking loads increasing for any reason. The example below shows the sequence of installation and operation of interjack stations, together with the effect on the lacking loads required by the thrust wall3.4 continued ob ob shell Pipe eck exes Lubrication can only work effectively fa layer is maintained between the exterior of the pipe and the adjacent excavated soil surface. Ina crude form this can be provided by a simple greasing of each pipe before it enters the ground, Once the ground has collapsed onto the pipe the effect of lubrication will oe really reduced. The lubricant must thorelore provide sulicient pressure to prevent this happening. Ifa slumy is used it must be designed to form a fiter ‘cake’ in the surrounding soil without excessive bleeding of material, anc be pressurised to the necessary level to overcome ground waler pressures and stabilise the tunnel If the lubricant can be designed to fil the entre overbreak then the pipes theoretically be buoyant. ‘The success therefore of lubrication in varying soils will cepend on the lubricant, the sophistication of the lubrication system, and the behaviour ot the soil in absorption of the lubricating material thas been proved that a fully lubricated crive with an annulus filled with bentonite, results in jacking resistance not much in excess of thal created by the shear strength of the bentonite slury. Bentonite slurries are recommended in sity, sandy and gravelly soils, but may create swelling in clays due to the absorption of wale, leading to increased contact stresses between pipe and ground, Non aqueous lubricants should be considered for conesive soils. Maer Dingommatic Caide 3 reser, 2 2 effective \pricabin Over prearising 3 : ar of lakecant i ee \ rrord hee 2 \ Riyeok Serace L] Zee 1 LA by ee3.5. Surface establishment The surlace establishment (or “topside” in jargon) is a support vervice of equipment required to teed the main pipe jacking operation The arrangement o these services is important from an ergonome pont at view, to provide an economic and efficient set up in the minimum possiole space This may be essential n an urban area, where space can be al a premum. The main support services generally include: Craneage or gantry for handing the shield, pipes and ancillary equioment Storage facilities for pipes and other materials Muck handling facilities, skips, slutry disposal, separation or settlement plant Lubrication mixing and injection plant A.contiot station for the main and interjack power units, remote control units Services: electrical, communications, water supply Pumping plant and disposal outlet General stores: workshop Hoardings, fencing, lighting, security and safety arrangements A:survey station Microtunnel tapsides have been rationalised lo provide a fully equipped and mobile container type control module, which sits alongside or over the working shall, and provides all the service functions, including gantry facilities, within a small contined area (see page 13) ‘The sketch shows a typical topside setup: es Tackg Pipe: & Labnication equipment Fewer pack contra) Torun. it Compecssor F. Spet ships oF disposal © Generator = pump es Fencing or hoardings GI BOO Cie «| hardin area3.6 Pipe jacking pipes Pipe jacking pipes and typical tlexiole joinls are Gesctibee and ilustratec in Part § of "An Introduction to Pipe Jacking and Microtunneliing Design’ The majority of pipes jacked are concrete, manutactured to BS 5911: Part 120: 1989. They should be obtained trom a certified manufacturer and quality assured to 8S EN ISO 9002: All pipes should be cextiticated Microtunneling pipes smaller than DN 900 are outside the current scope of B.S. 5911; Pat 120: 1989 and should conform to the Pipe Jacking Association and Concrete Pipe Assotiation “Concrete Pipes for Jacking Smailer Diameters (Microtunnel) and Unreinforced Pipes". The stresses attecting a jacking pipe are barrel and joint stresses. Research has shown that longitudinal tensile stresses are not critical and pipe barrels may be sately designed using simple compression thecry. Only nominal longitudinal reinforcemert is required. Hoop reinforcement is required to resist bending cue to ground pressures, and also to protect the pipe ends which are subject to complex tivee dimensional stress concitions. Joint stress is a function of the maximum allowable concrete stress, the siitiness of the packing material, and the maximum allowable detlecion angle between the pipes (see Figure 7) Detlection angles may be as a result of ceviation in ine and level tolerance or due to lack of squareness of the pipes. Although BS 6911 allows a maximum angle of 0.15° for lack of squareness (ie.0:3° tor opposing errors between two pipes). pipes manulactured by PJA members are generally to a control of 0,08°, and therefore this error may, in practi¢e, be discounted where this accuracy is maintained. Research shows that even with a small joint dellection the stresses in the joint are highly localised to a short part of the pipe circumference, the exact ‘area depending on the load transmitted and the stress-strain behaviour of the packing material In controled pipe jacks angles may range between 0.0° to 0.3° with a maximum value of 0.5°. tis not recommended {0 exceed these values, under high load conditions. Beware the allowable enc jacking load decreases rapialy as joint cellection increases (see Figure 8) Packers to the pipe joint must be resilient enough to take the unloacireload jacking stress and thick enaugh to take the compression ofthe maximum joint stess. They should cover the maximum exposed concrels joint area but be kept 20mm back from the edge o! the concrete to reduce the risk of local Se laaWher the jacking lorce 1s well Gistibuted over the pipe end area, i 1s appropriate to use a maximum concrete design stress based on the characteristic strength of the pipe concrete, |,,, divided by a materials factor of 1.3 and a load factor ¥ of 1.25 when using the design method given in Figure 7 (Ref, BS8110 Parts | & Il) Further pipe jacking end load calculation methods are awaiting publication under the CEN codes. Figure 8 of the Appendix shows the relationship between permissiole pipe end loadings at various angular misalignments for typical pipe jacks with packers of good stiffness and recovery, but iow Poissons ratio (ie.transverse stress) 10 minimise bursting joint stresses Further analyses of other packers may be found in the Oxford research data (Ripley 1989) Pipe manulacturers supply a variety of jacking pipes and catalogue pipes with flexible rebated and butt joints, special lead and interjack pipos, rmicrotunneliing pipes, and reference to such manulaciurers should be: made for precise dimensions and strength of the'r products, The pipe manulacturer will recommend packers to be used with their pipes. These should either be factory fitted, or sie fitted to the manufacturers instructions Pipes should be unloaded, stored or stacked and lifted in accordance with the Concrete Pipe Association recommendations, and in compliance with the appropriate heaith and safety regulations. Depending on shalt design, oipes may be lowered horizontally or vertically. It vertical lowering is required then the pipes will require to be handled in a purpose made cradle or iting device. It lubrication is required itis recommended that the oipes be provided with grouting holes and non-return valves Each manutaciurer will have a joint sealing system which may be a sliding type seal or an elastometric sealing ring, and may include secondary sealing tis essential that all pipes are jointed in accordance with the manufacturer instructions. Jointing of pipes in the working shaft must be carried out with care and in clean conditions A badly positioned jointing ring cant cause collar failure and may atlect the hydraulic perlomance of the pipetine. A Corcect. pecke3.6 continued Other materials such as steel, GAR fibrous cement and viritied clay are used in nipe jacking, Each material will have special characteristics and it 5 recommended that both manufacturer and installer work closely on projects designed for such pipes. Itis quite possible to jack pipes to a controlled curvature, either in an horizontal, or vertical plane, or both ‘This may be required to avoid an obstruction in the horizontal piane or to reduce the enilry and exit depth in the vertical plane, Ii-a curve is required itis avissed that the scheme design is discussed with both the pipe jacking shield designer and the pipe manutacturer, to ‘ensure that the load transfer through the joints can be taken, and that the shield can be steered to the curve required ‘The following tactors require to be considered when designing a curved pipe jack drive: Radius of curvature The abilty and design ol the shield, or TEM, and intejack Stations to negotiate the curve Pipe length and diameter Joint configuration and packing Transfer stresses through the joint Joird seal design Working tolerances and alignment control Thore is a clear relationship between these factors; eg a tight radius will require chort pipes ox maybe skew ended pipes, whereas a large radius may only require a moditied packing and sealing arrangement 10 starncard ber3.7 Ground movement Dung pipe jacking ground ~ ‘movement may occur due to the instability of the face of the tunne! bore, oF from the elastic unloading of ground caused by excavation (soe Figure 5), These have been relented 10 Section 3 of this guide and may be categorised as short term settlement and heave. Providing good practice is followed, the effect (of such movements should not be adverse, Long tenn settiernents will occur due to closing of the overoreak, ant may be assessed using methods developed for other forms of tunneling (see Figue 11) Pipe jacking has the advasitage Ural the overbreak is minimal and may be pressurised in certain soil conditions. The Oxford researctr discusses {grOUN6 movement findings and may be used in reference wih offer field observations where settlement 8. major concer, Continuing research 3 being ndlortaken en this subject and the PA will be publishing theie findings 1 due course, For the designer/nstaller a number of be guided points are worth consideration and are listed below. Problem @ Shallow constuction and cover to services Solution Consider physical suppor to services andlor localised groutiig Problem @ Effect on paraiiel services Solution Monitor then position and design wih sufficient clearance to avord interference from ground movement 04 drag. Consider grout support with stabilised face shield control Problem © Raiway cousior Road embankments Solution Minimise embankment movement by using a slip pkane method andlor imerjacks Protect shiele! drag exit wath a strong reception retaining wall It must be recognised that arly tunneling method wil create sore ground movernent, which may be significant or otherwise, dependent 1 the location of the tunnel related to third party structures, depth, sub soil conditions, water intrusions ‘excavation methods, and not least the skill of the construction team The cost that the promoter is prepared to pay for the best ‘belt and braces’ scheme must also be taken into consideration The unportant lesson 10 address 16 not that ‘there shall not be any ground movement’. but ‘what wait bbe, wilt seriously effect thied pany property, is if safe, nave we a monitoring system, what mover can we accept, and what are the ong fem ramifications? Ths point is laboured as the seaana contentious contractual matter alter dealing with water, Section 3.1, and 1 further discussed in Section 6 1Oxford research acdiesses the importance ol pipeline ignment and the relationship of arigular deflection between pipes against the requirement for line and level of a scheme design, The simple fact that a “rifle barrel” pipejack avoids problems as against a “wnggle” pipejack has been known and experienced by both promoters and installers over many years In an ideal pipejack no deviations would exist bul in practice wregulanties in {grounc conditions Gr cutting control will cause the shield to stray trom the ideal course, and this in turn will create addtional friction toroes and higher toads transfered through the pipe jeints angular detlection between pipes, and deviation from line anc level. {Lis important to realise the relationship between a tolerance for ine anc level, and a tolerance for angular deflection between pipe joints In practice itis quite possible to stay within a line and level tolerance yt go wulsige the angular detection tolerance and vice versa. The following skelches illustrate this powt . deflection faire Pipeline out of ang! dltecton toleance tx wi We and level tolerance The purpose of this quide Is 10 continue to educate all users of the pipe Jacking system to good practice, and to use the research knowledge to maintain and improve the skils that have been promoted by the PJA, Ungerstanding the relationship between alignment deviation and joint deflection is funéamental to good pipejacking. and research continues 10 develop sophisticated control systems to measure both the above criteria The Oxford publication. ‘Pipe jacking - Research Results and Recommendations’, refers in some delail 10 a three dimensional contio! system and graphical method, which allows decisions about steering corrections to be made to minimise subsequent joint anglesToletances of £75mm for line and 50mm for level ave been generally accepted by the industry as being both practical for the users final design, and aise providing sufficient latitude for the installer to cope with the steering demands of varying ground conditions ‘ith the increasing sophistication of pipe jacking equipment arid contiol ‘slems, there is an increasing demand for tighter tolerances for some activities (e.g, lat gradient sewer schemes) Also it should be recognised that tighter toleran ricrolunnelling, especially in the smaller diameter range, taking into account the ciameter/pipe lengthyjoint detlection angies ave required for if ighter tolerances are required, it must be understood thal hese may not be possible in all planes, and therefore the promoter/designar must decide which tolerance (ie. vertical or horizontal) is of most importance to the schen For a sewer desigh 1 may be thal level Is more Important that line, and i tolerances could be revised to say + 150mm for line and +25mm for level For a sleeve pipe to take a steel gas main, itis probable thal both fine and “Tan level are of equal importance in order forthe sleeve to accept the rigs carrier pipe. In such a case it may be sensible to design the sleeve pipe to | grovide an internal diameter greater than a norral fifo allow for tolerance 4 variations in any plane. ‘Whatever tolerances are specified it inust be emphasised that the ultimate jon is the joint detlection which must not exceed the value used in calculating the pipe design load. The following graph provides some be guided advice on this pownt4.1 4.1 Steering control Good steering contro! requires the following: @ An acourate survey between the thrust and reception shafts @ An accurate set up, break oul and shield entry @ An acourale and steerable shield @ A control system to monitor line and level @ A system to measure and control joint deflection between pips it cannot be emphasised enough ow important itis lor an accurate set up, break out and shield entry. A shielo at has ben sent off i the wrong direction wl equi that every pipe behind it will have to ‘ollow the wrong path created by the shioid, wth the ‘consequential Jpirt deflection problems ares increased friction loads Shiteld eniry should be stow vath frequent checks and the shiekd leering positioned at neuial until tha whole shield is buried, using the body of the shiold for ssegsing Tether than the face steering jacks Beware of unelable around concttions and 210i loss of soil on ety. This may cause ditteential mressutes on the shield Nutrial surveying equipment is quite adequate to provide an accurate survey between the thrust and reception shafts, Wig advised that the ialial survey be carried out twice using independent survey stations, ands preferably ditferert surveyors Also of great importance is the transfer of the survey to the bottonn of the shatts, and a discipline for ‘checking survey stations on a ‘egular basis throughout the pie jack, For good practice follow trese be guided pomnts, Make sure the jacking frame wil not deliect under the weight oF the pipesishietd. Secure the jacking frame to the cortect line and fevef on a firm base that wall also take shock loads, Make an allowance on the jacking frame fo account for the overbreak of the shits to the lead Jacking pipe, 80 that the pipe les ceria fo the shine (Check that the thrust wall, backspreader and jacks are at right angles or aligned, depending on the jacking ig, to the ine and level gradient of the Gesignes | bore. Sel up the shield and jack it up to the shalt face or pipejack eye, and check that tis corecty allgnec before excavation commences If ising a laser, mak sure that itis rigidly mounted and fixed independently be of the seff feveling type re-checking“Gren Pipe jack shields must be accurate (2. cylindrical to a fine tolerance) and should incorporate a steering arrangement In anand shield this can be simple jacks for adjusting the shield in relation {0 the lead pipe, but a TBM will require a steerable head which articulates relative to the body of the shieid fa shield is not manufactured to tolerance or has been damaged during Use, it may create its own steering characteristics which will cause it to, “crab or roll out of control The shield must be provided with a target as near to the face as practicable (on to which normal instrument surveying or laser beams can be set 10, provide a control for the tunnel miner or machine operates Constant monitoring and small steering corrections are essential to maintain good alignment control. ‘A control system to monitor line and level can be as simple or as sophisticated as the diameter or length of the bore determines. Normal surveying instruments have been used for years and laser technology is now common in all fields of civil engineering and tunneling More sophisticated methods such as gyro compasses and computerised automatic control systems are available, Whichever system is employed the important message is that it must be fully understood by all the operating personne! Checks must oe regular and recordad, and the system must be checked back to the main survey on a regular basis. It misalignment does occur for any reason, itis important to keep steering corrections small in order to avoid large angular deflections of the pipe joints It-small corrections mean that the pipeline will travel outside the scheme design tolerance, then itis better lo exceed the line tolerance rather than the level tolerance. Depending on the size of the misalignment, a philosophy of striking a new line and level target is always better than trying to go back to the original A system to measure and control joint deflection between pipes is required to ensure the angular detlaction limits in Section 3.6 are not exceeded Peagnal Wwe hE —— red chasing ongral ahigirmerd4.2 Loading control ‘The thrust loads necessary 10 install a pipe jack are created by the length ano diameter of the bore ans the forces generated in the ground conditions. The loads that can be applied depend on the strength of the jacking pipes and the ability to construct a jacking anchorage and/or provide interjack stations, The thrust load is normally generated by powerful hydraulic jacks, and must be transfered to the pipes and thrust anchorage by using strong distributor plates. In the thrust anchorage this can take the form of a back spreading stee! plate 10 cistribute the load evenly onto the surrounding shat or ground, To transfer the load onto the pipes it is advisable to provide a strong thrust ring and to use sulficient jacks around the ring fo provide even pressures ltis recommended that the jack arrangement is designed to provide a resultant thrust lead which i concentric 10 the pipe to avoid covertuming moments, ‘The power of hydraulics is not always appreciated. Kinetic energy is a function of load and speed and damage may be caused depending (on the ability of the receiver to absorb energy. Pipe jacks reauite large energy to install, but jacking pipes are low speed energy absorbers. Hydraulic jacks should theretore be designed 10 give high loads and low speeds to avoid kinetic damage and provide good jacking control. The jacking system must be supplied with a device to measure the jacking loads being applied, and for safety include a control valve to limit the system to the maximum allowable design load. itis recommended to provide a factor of safely to bath the ultimate for9s calculated to install the pipe Jack, and the design thrust load of the pipes at their maximum deflection Interjack stations wall incorporate a umber of jacks distributing their loads through steel plates around the pipe circumference ILis sensible to cortelate the speed of the interjack stations and the main jacking station in order to achieve the minimum time to move Ihe whole pipeline forward. Interjack stations should be considered as insurance policies and installed at regular distances commensurate {0 the overall design forces anticipated, and should include a good factor of safety. itis not unknown forthe scheme design forces to increase substantially duo to changed {ground conditions or behaviour of the ground4.3 4.3 Record controt Apipe jack 's only completed when the shield enters the reception shall arnt is disconnected from the jacking f: eS and the interjacks closed. In this respect and until this moment the pipeline may be considered to be ina temporary work state and requires constant moritoring, Monitoring without recording is a halfway house and il is recommended that the following minimum records are kept. The table below indicates the information that can e obtained both for the pipejack in construction or completed, which can be invaluable to future Pipe jacks to be constructed Record Main survey checks Line and level Shiela position Pipe rolling Joint deflection Main jacking load Interjack toad Shield toad Total load Surface checks Information obtainable Movement of shafts, surface to tunnel survey check Sinking, scouring, alignment Settlement considerations Crabbing, ling, sensitivity Differential soil pressures ‘Stress limitations, alignment Thrust wall li Soil friction characteristics Start uo and time delay loads Pipe stress limitations tations Friction loads, time related loads Face load, obstructions, slurry and/or earth balance requirements. Equipment lasses and efficiency Overall ground an¢ friction loads Short {erm ground loss ar heave Long term settlement A recommended pipe jacking record sheet is shown in the Appendix, Figure 12.ections 3 and 4 of ths guide have covered matters relating to good practice for scheme design and installation of pipe jacks. They have been written to encourage users to good practical and commercial evaluation Othe parts that make up a successtul pipe jack contract. However well advised, humans make mistakes or errors, rarely deliberately, but more likely from pressure of time, misunderstanding, forgetfulness, poor disciplines and checking. How often does one check the oil level or tyre pressure ‘when hurrying into the car to attend a deadline meeting? Good pipe jacking is a discipline to keep out of trouble, rather than get out of trouble. Providing the user understands what can go wrong, then the pipe jack should be successtul This section will identity a check lst of poor disciplines and the resultant likely failures if these disciplines are ignored or given low prot No list can ever be exhaustive and all parties to a oipe jack scheme should be prepared to add their ‘own disciplines peculiar to their scheme, Poor iscipline Inadequate soil investigation Wrong selection of pipe jack shield Poorly designed or sized working shat Under designed thrust wall Non assessment of friction foads No allowance for interjack stations 0 lubrication Unplanned requirements for surface establishment Insufficient research into pipe design, joint sealing, packings Poor sat up and shield entry Inadequate surveying control No jacking load control or record contro Likely Failure Stalled or aborted pipe jack Poor production, tack of face control, surface disruption Uneconomic working conditions: water and soil intrusion Shaft damage, contract delay design length failure Stalled pipejack, over stress. ‘on thrust wall and jacking pipes No margin for change in soil friction characteristics or hold up/delay load requirements Uneconomic working conditions, double handling of materials, interference with public rights Pipe failure due to jacking overload, ground pressure, aborted pipejack, non-watertight pipeline Bull in problem throughout the pipe jack, with higher triction loads and joint stresses ‘Scheme tolerance exceeded, joint deflection rick Pipejacking, anything could6.1 Contractual considerations Whist the mechanics of pioe The responsiblity for drawing up jacking is controlled by the law of contract documents fes with the science, the construction is more client and such advisors that are than likely to be controlled by the instructed law of contract This guide is not intended to be Coping with the faw of science is other than a practical look at the not onerous, providing logical factors that contribute 10 good oipe decisions are made when changes jacking, but as liked inthe are demanded introduction, no pipe jack will be successful if part of the chain is a rth the interpretation of the Coe re eter potential contractual weakness, law of contract can be more contentious, but confrontation can _Listed alongside and overleaf are be limited if the parties involved are some af the key points which need aware of, and set out to avoid, the consideration when drawing up a pitfalls. contract. These will go a long way to avoid contractual Contract documents should be misunderstanding. drawn up by the promoter/client in order that pipe jacking contractors can make sound engineering and economical offers to carry out the work, However, too often vested interests, such as transfer of risk, inadequate site investigation, unclear engineering requirements, onerous clauses, amendments to standard conditions (contrary to those accepted and agreed by industry bodies), lead to misunderstanding, confrontation, dispute, claims, and litigation. None of this is conducive to the proper and timely construction of the work, and will invariably lead to loss of goodwill between the parties to the contract, increased costs, ‘and more lees for the ‘egal protession. Conditions of Contract Where possible use standard forms of contract, Many hours of effort and thought have gone into production of these forms, with representation {rom most of the industy. It changes are necessary due to a specitic requirement, then make it clear to all parties. Time for completion So often litle oF no thought is given 10 a realistic period for completion of nepepcogeercwaiee EEd works. ‘The client will have concerns with regaid to finance programmes, planning requirements, design periods, legislation, and numerous other factors, ‘The pipe jacking contractor will have. conceins to current workload, ullisation and availabilty of equipment Tne pipe manufacturer will need to check the stock load and any special design requirements, It the pipejack is part of a main contract, time planning is of great importance to achieve completion. or part completion, in order to avoid disputes and/or delays which could {ead to arguments including liquidated damages. When ready to go out to tender, thought must be given to a sensible lime to obtain a considered bid (laking the above points into consideration), time for a proper evaluation of the tender offer(s), and award of contract.6.1 continued Specification Specitications are required to detne the standard of workmanship and materials required for the contract They should be clear and take account of standards and codes appropriate to current practice the client is uncertain of the rmarkel and technical skils available then specification in the form of a performance contact is a uselul tool. In such a contract the client can speciy the performance required lor the finished project. This type of contract is especially suitable to pipejacking and microtunneling because of ts specialist nature. However, i requires thal the installer has sufficient experience and skills to otfer a proper engineering solution, and thal the client's engineer, or designer has suficient knowiedge {o evaluate the solution on offer Bill of Quantities Although the Givil Engineering Standard Method of Measurement (CESMM) is used consistently in the UK, it isin fact not garticularly appropriate to pipejacking ang microtunneliing, The PJA are currently studying a preferred method of measurement and this is planned for publication in due course Bills of quantities (8.0.0) ae primarily requited to provide a contractor with a basis tor pricing the works which can be compared with other bids. Their secondary role is to provide a basis for evaluating the works for payment, both for the work specified, and any variations, To be of value the B.O.Q. must be accurate in quantities and activities, and be linked to the specification, drawings ano soil investigation report, so that there can be minimal argument between the parties to the contract as to what is required Sketches with a few unit rates will only lead to misunderstanding Prequalification To ensure good installation 1s recommended that suitable contractors ate requited 10 demonstrate that they have the neccessary experience, skills, finance and management to cary out the work.6.2 Health and safety The Pipe Jacking Association regards health and sately matters as being of prime importance, ‘All employers in the construction industry have legal, oersonal anct ‘economic reasons for reducing risks o! injury to personnel, lamage to expensive equipment, and wastage of materials. Safely matters are referred to in various sections of this guide, and attention must be given to the overall safety of the pipejacking operations. Many of the features of etfective health and safety management are indistinguishable from sound management and construction practices recommended within this document ILis the policy of the PJA to promote and encourage health and safely, and welfare practice. Clients, designers and contractors have a duty to bring their business expertise to bear on health and safety, as they do on other aspects of their organisations. Health and Sately legislation is in four stages: @ Acts @ Regulations @ Aporoves Codes of Practice @ Guidance Notes Regulations tend to state the scope of compliance, leaving more prescriptive aspects Jo approved Codes of Practice and Guidance Notes. Referenced in Section 10, are documents which are applicable bul not exhaustive to good practice Visrecommended that these documents are used as a sound starting bbase for sale pipejacking and microtunneliing,6.3 Training The object of training personnel is to achieve the optimum performance in tems of quality, efficiency and safety. Careful olanning is required to: ‘Analyse each part of the work cycle to determine its criticality to the complete cycle of operations. Determine the most efficient and cost effective method of undertaking the work by relerring to @ Company and personal experience @ Equipment manufacturers’ experience @ Suppliers’ experience @ Local knowledge ‘Any deticiencies in knowledge oF experience will quickly become apparent, and can be rectilied by appropriate training There can be no substitute forthe hard won experience of both equipment and material suppliers. Their experience must be sought and full use made of their in-house training schemes, simulators, site operators, training and handling maruals, Today the cost of training is insigniticant wnen compared with the cost of equipment, its operation and maintenance. An untrained operator can incur unnecessary costs for the sake of a small investment in relevant training, Site personnel fit into one ot three groups: (@ Pormanent contractor's staff @ Experienced travelling operatives @ inexperienced locally recruited operatives Each requires a cif nt type and depth of trainingPermanent contractor's staff Should be broadly trained in their ‘company requirements with specitic lraining covering the following: @ Geotechnical work and the interpretation of field and laboratory results ‘@ Survey including the correlation of surface and underground surveys @ Underground working methods, specialist materials, olant and ‘equipment © Understanding the influence of underground work on surface installations, buildings and the tke @ Tho requirements of current Heaith and Sately Legislation applicable to the work being undertaken Experienced travelling operatives Usually have a good command of the practical aspects ot a variety of tunneling techniques. Their suitably for the work to be undertaken must be assessed, and any deficiencies made good by an appropriate training course. Such courses could include: @ External machine manufacturers, or material suppliers courses @ In-house courses, specilically tailored and directed at chosen parts of the work content Equipment operators require to be carefully chosen and specifically trained and rewarded, on a quality and cost effective basis. ‘A number of colleges, run full ime courses dealing with both theoretical and practical aspects of tunnelling, and National Vocational Qualifications (NVO's) are to be introduced for tunnelling operatives ltis recommended thal such courses and certification procedures should be investigated and used if appropriate. Inexperienced locally recruited operatives Traditionally this source has provided some of the manpower in the industry. The operative arrives On site for the first time, often innocent of the dangers, the work content, of what will be expected to be done. Training needs ave immediate and must include. @ Basic site safety (@ Use of protective equipment (© Ful training for the duties required to be undertaken (@ How these duties fit into the cycle of work and any personal responsibilities The newly recruited operative must be fully supervised, and ideally not lett alone until adequate training has boon proved and demonstrated. It is recommenced that all catagories of staff and ‘operatives attend regular ‘tool box’ talks on appropriate subjects.Soil investigation CAvaiabity: not way not? Commission as necessary ils it suticient? Experience trom previous or Shield of tune ling machine Ci Excavation method: Production capabally CPipetine dimensions Ci Face support and/or pressure control (Access for maintenance: Breakdown recovery LJ Adaptability to unforseen ot changed ground conditions Working shaft [Location and dimension CiConstruction method C1 Suitability 10 accommodate the shield and other equipment Ci Control of ground pressures and water intrusion C1 Thuust wall requirements CP pe jack eye tacilty (Conversion to manhole or permanent structure Drive lengths C1 Shield face loads CSet weight of jacking pipes 1 Ground friction loads CMisalignment allowance [Time delay allowance CJ Interjack requirement: closure provision GiLubrication arrangement Surface establishment COffices and accommodation CEquipment layout CPipe storage and handling Ci Graneage or gantry C1Speit handing: storage: spillage CiSeparation or stury control Fencing and hoardings D Tratic controt C1 Safety and security Pipe jacking pipes L1Pipe type and joint design Cl Stress requirement: ground loacijacking ‘oad Coin deflection requirement: load limitation Cioint packing recommendations Cuboint seating arrangement CiSpecial pipes: lead pipe/interjack pipes C1 Requirement for curved pipe jacks (Lubrication factty OTanspor, handing and storage considerations Ground movement Location and protection of services Monitoring system CBackgrouting as requireaSteering control CiSurlace survey: double check procedure: C1 Transter survey to pipe tunnel level D gacking frame and thrust wall alignment Dishieid entry procedure Pipe tunnel survey policy laser: target Monitoring method: freauency: information required TDeviation control and monitoring Remote control and camera checking for microtunnelling Recording procedure Loading control CoEstimated jacking loads Ci transfer thrust ring and backspreader Ci Power pack and jacking arrangement D Jacking ‘oad measurement procedure and factor of salety Dimerjack toad measurement and control Record control Main survey ClLine and level Ci shetd position Pipe roting Cuoint detection Main jacking load Cinterjack load shield toas O Total load CSurtace checks Other matters C1 Contractual considerations (Health and satety C1 Training Ci Regulations The preceding check lst, whilst not exhaustive, is abe guided list which covers the essential requirements for the best practi for installation of pipejacks and migrotunnels There are many other factors that need consideration to complete an installation which are not appropriate to detailed discussion within this guide, However, in order to be comprehensive the following list is added for the consideration of the reader: Enviromental and noise contro! Public awareness and advantages Public health and safety O Third party safety OWorking conditions and satety Employment conditions: site faciltios Working hours. emergency poticy Cason with other services/authorities Good signing of the site Ditipoing and offsite lorry movernents CiCompletion and clearance of the site8.0 Append Page 43 Paneipat syrnbois, Figure 1 Face stability in cohesive soils — Figure 2 ‘Tunnel stability in cohesive soils —_ Figure 3 Tunnel stability in cohesionless soils Figure 4 Mode! for ground ioading in cohesive soil alter Haslem (1986) Figure 5 Calculation of ground closure Figure 6 Mode for ground loading in cohesioniess soil after Teszaghi (1943) Figure 7 Jacking forces from linear joint stress model Figure 8 Permissible pipe end loadings at various angular misalignments Figure 9 Uniaxial compression tests on joint packer material (Milligan & Norris 1992) Figure 10 Conditions for local yielding at the tunnel surface Figure 11 Calculation of long-term settlements Figure 12 Recommended pipe jacking record sheet Figure 13. Soil parametersPrincipal symbols magoce mms Pp aot ceo ~ Boe erase aay pre gey(H+D,2)-T-s, Where ¥ = unit weight of soil, s, = undrained strength of soil and T, = stability ratio - see plot below (Atkinson and Mair 1981). In pipe jacked tunnels the unsupported length P is usually small or zero, and P/D,=0. eg. for y = 20 kNim’, H = 4m, D, = 2m, the plot gives T, = 8 hence oy = 100-8, kPa and for 5, > 12.5 kPa, no support is needed. "p prevent blow-out due 1 excessive face pressure, 6,<7(H+DJ2)+T, In both cases, a factor of safety of 1.5 102.0 on §, is needed to timit heave and settlement in soft clays, for example see below (Mair 1987). In this case, say y = 20 kN/m’, D, = 2.0m, 5, = 10kPa, then y DJs, For HID, = 20.and dividing 5, by a factor Of safety of 2, 6, = 20(4+2/2) * 8x5 = 100 + 40 hence o must lic between 60 and 140 kPa, {a) Potential instability of tunnel face arising from insufficient face pressure _Saestone (>) Potential blow-out arising from ‘excessive face pressureFor the tunnel behind the shield, the conditions correspond to the case in Figure 1 of P/D, >=. The equation for calculating the support pressure required to prevent collapse is as before o.="H+D 2), Which eye rearrange to ine 9, Dy ar Se We(H/D.+ 12)-T, ‘This gives rise to plots shown below. Again,values ofc less than zero indicate thatthe tunnel is stable without any support pressure. Note that for microtunnelsy Djs, <<< 1-0 in most cases, and the tunnel bore will normally be stable. For example, for H/D, = 2, and y DJs, = 4, from Figure 1: T, = 4 then os, = 4x25 -4 = 6, or directly from plot above, ie for s, = 10 kPa, 6, = 60 kPa.For tunnels in cohesionless soil without a surcharge on the surface, the required support pressure is independent of the cover depth and is given by 6,= DT, ‘where Tis the stability number given by the plot below; itis a function only of 6, the friction angle for the soil ie 2.0} 10 20 For example, if y= 18 kN/m’, D, = 1.6m, and 6= 35° from then the plot T, = 03 and oy = 18% 16x03 = 86 kPa the tunnel is at shallow depth and a large surcharge 6, acts on the surface, the ‘weight of soil may be neglected and then 6,= 0,7 with the stability number’T, as given in the plot below. Note that both solutions apply to dry soil. Water pressure, if present, must be added to Gand the buoyant weight of soil used in the first equation.9, HOETEEE TEEPE EERE EEE HHEATHT TEETH AE teetttteteettt ttt ttt THEE EEE eet eee ttt ttt For initial vertical and horizontal stresses in the ground 6, and G,, the reduction in vertical diameter of the tunnel bore due to elastic stress relief is given by 3 ")D.36,+6,) s and similar the reduction inthe horizontal diameters given by 8, = (4D, Go,+6,) E, where E, and v are the Young's modulus and Poisson's ratio for the soil, If internal support pressure p is applied, the symmetrical increase in radius is given by 8, = Cen,Formula Correction — Guide to best practice for the installation of yejacks and microtunnels The formula on page 50, figure 7, re permissible jacking loads has an error and one of the negative signs is misplaced. The correct formula appears below. Permissible Jacking load * = (?-h2)"] ~ hL=R cos 4 : Bros] Siete ein for-r> hor The second formula, for h > r, is correct.From the Australian Concrete Pipe Association linear stress approach ermine acing oad Oo 2 HZVAZ fg? is 2 egg t{h-| 2 egg:1fhi = Eh) {210 Wry? - (7 - YP] a ‘cos’ Gs" cos" A +h Rn? (e-Hy"I} When h > r permissible jacking foad & ao {231 hy?]-h IZ Rcos' (Ay) +h(R* nye}eo} Sunyoef pa papustuiooas winworeur szeznioegnuetd oun we poreuuLoN are sydes8 aU, :10N (.) vousoyap 2einsuy (_) vonsayep zensry L_s0_ 0 40 90 so ro eo 70 10 0 160 0 40 90 so ro £0 zo 10 0 S 388 (2uvo1) peor duper — sa ws st Jay ww 1 wus azoc 'a'O supped ww O¢81 G'T Supped | ‘was oztz “a'0 eid wu (ORT OT adi (s20v01) proy Sunper ZERSE8R BR (dtd .€. AWAHIS) (Gdid W,aWAHOS) ‘eR OMB (2) won2ouep semfy (6) wonsoyep senuy 60 _s0 40 90 _s0_r0 cv zo 0, s 2 (2vu01) peor Supper — sanz{esta} NOISSAENOO oy oz od é 2 (cami) ssauAs, “11a aunssaud wus + AGW wT ALISOAWOD{transverse distance from centreline Li i ‘Settlement volyme (per unit advance) Maximum curvature hoaging 7 | M/S =a'= 0.446 Smax SS axe? (7/27) ay = { *Maximum horizontal strain (tensile) i = 0446 San / of inflexion (y =i, 8 = 0.606Smax) Maximum slope = dS = 0.606 S, - max *Maximum horizontal displacement = Maximum curvature siging = 13S.» sai] “Not applicable to granular soils | *Maximum horizontal strain (compressive) = Sma) | # Tunnel axis level From O'Reilly and New (1982) ‘Surface settlement S at given point =s,,e¥P%= St evn? Nam where V, = volume lossunit length on 6 mw wn Depth of tuna ais below ground surface) BOR ‘Transverse distance to point of inlexion, im) imop-o2 75 oe a SL ‘Dept of tunel axis below ground surface, (mm)otal Length; Front Shield Jacking Load Line Level Main | Interjack ‘Water Intrusion: Remarks: lt is recommended that for each drive a line and level record 1s produced together with a jacking load and progress graph. 75mm. OLIN 75mm Oman LEVEL, SOc oust Tae9eE) guernsh? Shield Load | DISTANCE / DATE Jacking Load and Progress Graph For mactune dives other information will be relevant, dependant on the shield excavation method & 9 © Slurry pressures, viscosity, discharge, flow rate © Shield roll, pitching, steering adjustment © Thrust rate, cutting torque, soil discharge ‘These can be adapted to suit specitic scheme designs9.0 Scheme A 9.1 Overall scheme requirement Ahand shield driven pipe jack of internal diameter 1.5 metres, 180 metre length at a depth of 12.0 metres to invert, in ground conditions of 7.0 metres of wet ballast overlying London Clay using steel-banded butt jointed concrete pipes. 9.2 Specific data to the scheme intesnal diameter of pipe 4 External diameter of pipe D, ‘Wall thickness of oipe t Depth to invert of pipe Depth to axis of pipe , Length of drive Water table - below ground level 9.3 Calculate © Tunnel face stability (© Tunnel bore stability @ Elastic ground closure ‘@ Local yield of ground ‘© Ground movernent ‘© Pipe friction and pipe joint loading 9.4 Workings 1470 mm (References are to Figure Nos in the Appendix to this guide, unloss otherwise stated)CRA Tye cl Cy fraud Conditions 7m bahest, orenlying kondon Cay Water tbe + Sm BEIOW) GL assume London Cay has V-vaue of ~ 30, endvaund si Swiss from literature , eravntd BhAENER of Kanoon clad fer: trams ~ T50Su , giving Eg = 100% wo kh Depth to invere oF pipe = 120m ; = rymm (1scomm nena 1D) 10 & pype aeceaaaae » asm BEEN Zike satwated vik uxie bamast = ¥, =19 W/m Saturated unit war 7 oncom ty = X= 2 Aly Jra2 JOPRA VEHACR SHES at ane Ge = Keys n2/-22khy AiMor prasues appoumale’y Ayovostatic. on top G kongon Clay, . Water presiute at ax of. funnel Up = fras-e- 5)10 = 97S Khe * ene rotates Ab fond OXIS. 6 = OU, = ys KPa Bail Kondon cay, catty Ko = Ie neonate cee Emenee lob! = pep a ieheg = 00 $ 6+ 6, =) Total hongontad Sess at forinel axis & Us 297 Shla pes Kaen clsenise:|=| Lp = (300mm heres oinynttar = d= 1470 Won Hyckvess t = 65mm height of fre W~ My (0p*— d*)2% = 203 KnTunnel face stabliiry - Ref: Figure ! & = & Te Su for stabil Cover H = 12-0-14I~ 0-165 = (0-4 Hh = 595, 2 = 0 for shiet0 close fo tunmel face ® De From plot Te = 9, -. G—E Su =222- 1x 135<<0 < Fonned fale very stable, F.fS > Tanmed bore stability - Figure 2 A= 595, L asco, + EAHD e fro % 6-= 22-4:2 x BS << 0 ++ Yuame bon. vay stable, FG8.22-59.0 Worked examples Flashic grouma closuwe - Figuse: 5 = (-Y) & BSED er en & = CYOp BSS) Es ee teat ati Hating Aer cir = 922,Kh, Sh 298 kh, Es= wo x1oekh, Y=05 pe Lem Ga gies )=/3-0mm 8, = S-]mm. Me longer tams ckformation Wilt meease aoe fo dramage Tor fut dramage E'= G'=GnEs wohiest typicamty y'va.2 ality) “QHD (Bmie G, the sheen modulus, 18 the Sane vi bith Olyainecl ana undated conotions .) Hewte E'=0:8E, , 8 = Ibm, &'= (8-Buan on oie ae revert Etestic cbfovmations cousins am imihad overbreak of 25mm. on sore be acted EE ensLoved yitt0 of gromme — Figeve tO Check locar stresses avcund tunmel opening & = 222 kk, Gh =2BKR KAR 13 +. at Conn of tunnel fe (ec ctrewuufevential Stress site TIFK= BO 60> 666 KB, at ane of tuned, LB = 3-K 2166 2. Gaz 368 kf toced yitoung wit oocurif, (&—%) 728i fer-unpressiised tunnel F>0, and Fe, Fn vith 72S, =2IOkKK 19 will OctuY Unless fumnned I8 PREESUSE) with Sustable Gl Mabricamt” stung fo & pressure F 666-270 = 4OOkA, Uf boca yietoaug 18 AMON, prediction of Contdet stressés berween pytand eae not possible without Sophisticated frmite Etetvert anaksats. wat Ye By) be reduced 2 parent sita the Untial overbreak ,anTuntess Surface or pace ae a major probiem (ste later), yne crevboeak cond bE inCveAbEd 10 SBt4 HOmm On diameter,Worked examples Ground movernene - Figure F cvertrtak 2 babes Oe Sei orhuiveter used (See previous), Yen gromd loss for comypstete, sure OF ground onto pipe, Gry mann ncdynun SErtternents, YG = ILO 812 1807)'= 0.uley. mila (45%) Because face stability 1s Migh, assume ground loss there neghgibte fora Te ons yp I o a ter = 594m fer 3= pth 1o-tunnelanis = 125m THM Sugg = VE = 7 Imm Yairi Poerteak inueastd fs Somm on clismmeter, “ Ges 1e) = 0/43 Snae = Fm (n citner case wioth of sterner Ih = bc = Such @ wide, shaMon setttement Nei ana 10 am: problems URS there ave Stusitive Sruchues or services above * Cppeine!Pipe friction and Ape jou loa0ug - rgmes 7, 884 For estimation of prpoe Prition, sce vesutls fram tonor Oak , (F1G 4.9 85.3 of the Oxford Report): at Suman depth fig ore eer fore apereee Sy AN /m . To attow for incveages in resis: due 10 StHPPAGE,, As bg 301, giving movinnun of 81hNm pone £0 ace ppp sunae ee it ge ism Asus permed design criteria, Ynen OM informarion.gwen by Bee} ‘ACH GES arimune Pipe, jacking (oid at Anguisn a¢echon ¢ 05° = 440T (4300KM) Ther length & pipe betnieen WntegAcks = 4300 > 53m tor fret length, weld, Mead Gf ~30 kK: tale §: it th ef ope beeot iam N (See 1 of Orford Report) «|. Aavision Bhovtd be mack for 3 soterpales, ie fuse After 3 ppes (45m), the others After pipes 33 (1Sm) and 58 (45m). Motors ing recows and us Gf neyo. fnaghe acto pe ee "0 Bb indeed pooh.| 9.0 Worked examples Summary of Scheme A Tunnel face stability Very stable Factor of salety 5.0 Tunnel bore stability Very stable Factor of safety 25 Elastic ground closure To prevent elastic deformation causing closure onto the pipe use an initial overoreak of 25mm on diameter Local yield of ground Local yielding will occur une: with a suitable ludvicant slurry. ne tunnel is pressurised to 400 Koa This may be reduced if the overbreak is increased to 40mm, subject to settlement considerations. Ground movement Even with overbreak up to 50mm the settlement trough will be wide and shallow, and is unjikely to cause problems unless there are sensitive structures or services above. Pipe Friction and Pipe joint loading Using a chipboard packer 130mm wide, and allowing a maximum anguaar joint deflection of 0.5°, the maximum pipe load is 440 tonnes. From the estimate of pipe friction, provision should be made for 3 interjacks at 45m, 95m and 145m. These may be reduced, provided monitoring indicates lower friction figures, Using a factor of sately of 1.5, itis suggested that the thrust wall bbe designed to accommodate 650 tonnes.Scheme B 9.5 Overall scheme requirement {A slurry TBM shield driven pipe jack of internal diameter 1.8 metres, 300 metres in length at a depth of 7.0 metres to invert, in ground conditions of wet ballast using steel-banded butt jointed pipes. 9.6 Specific data to the scheme Intemal diameter of pipe 1800 mm External diameter of pipe Dy 2120 mm he Wall thickness of ppe t= 160mm_ Depth to invert of pipe 700m hrm ner Depth to axis of pipe »! | dim] | | Llld Length of drive 300m below ground level 2.0m 9.7 Calculate (© Tunne! face pressure @ Tunnel face load {© Tunne bore stability @ Ground closure ‘© Ground settlement @ Pipe friction {© Pipe joint loading 9.8 Workings (Reterences are to Figure Nos i the Appendix otherwise stated). this guide, uniess0 Worked examples frown) conoth Asdunne gre Sand, SPT N-Vanes = 25 browned Gy EL pecoK (srroudl) = 100 x 103 KPa Assume Water table at depth 2On. betow gromad Lever Saturated ex ne paad TS KNm* Bucrpome ‘Son 29-5 KN/m* Water ppressiube at Bus g tiumet » "4 x 10 = yl kh TOBA VEVEICON SHAKS At AUS f Randel 6, = 61/95 = HIM fective vata shexs at duis Ferumine 6! = 19 41 = 78hle. Bed he arin aragie of soil = 38° ven, ho = 1 SH P= ones re Novi Shess ar axis 6), = 0455 x 78 = 35: 5hhe hori’ SHO At Atte Dy = 35°57 4 = TSKTanne! Poce pressure Mmovenents at tne FALE 2A num, Sy Pressure ShOWd be 80-100KR bo keep egal fo tofed hori SESE OF 8UG venter, 100K fa, TOPE, pressive l0bd =“100'T 212? = 350K (36T) 4 Tame! load - Frguse 6 i adoytion fo [0d due fo FAKE pvEssune cOtulared above (37) there ill bé tue Stud and friction on rhe WOUNC reststaMee On The ee ee lecsliemeleipee duevicatiow vs Ve. Assume tins leugin 4m for the Stkt0, pus offen ‘The first ere emer, eens ove this Mength. se. grin acing Paedel fe Fip-e Gi thee 4B Daten Case a) Qlsin (45% %) aiese (954%) 17 Pi oe om Gs ois = 285° 0295 - Kind 20/076 C+ Ssin) & ft depth Im H= 20, O =O) = 19-5 (1-€9.0 Worked examples 45 nfm 0-323 BOW F = 20m 5 (i-th) then Atan ge 8 and %' =, e073, y! (970828) 01076 = 25.4 t 244 = 498 ka then % = K(G't 05 YD) = 17-7 ano frictions vesistae, Fa Toe §)tan& El taking 8 0-876 = 287° . F FHVS Kim + For lengin of Im, frictionar vesisrame = 1076 WN Aa RRA ceimatee eeereg eee vesistane, then tered = (076 F 3507 200 = 1626 kNTunnel bore Stabs uty - haw 3 pro.r MNE, = I-P) 2:12 (3x TR BSS) = 55mm 52 i-v) 212 (143x355) = 38am MK KESS CU WaNO movement dunt to shuny pressure lees HOMEY PressiMe ~10kfa. iS e a & = (#P)p Dp = Ohmaim (negugibe ) : § « - Aonided adequate shawny jin is proviteo|an overtéreake on Aiameter F 20mm wilt be RdEgM mamtain an annuus g lmericant aroundl the prpe Ground sett enneud- Figuwt I! foie a te, Phe oressiet is provibled, serttement of tunnel face ote ji “ fo fut Sustcig te (possi uly & 8 long tan? fale Bveupresevniged), Ki > IE (2.142— 2127) = 0.0669 mi/m 9%) a Fam, C= 0283-012, and 3= 61 Wf = 15%, Then, total wioth oF seithement trough = 66 = 45m Ano -maLimum sertrement = Y, 168mm. Vat i 699.0 Worked examples Die friction. fer, toricated p ope, buby: Ora Opt: Te 10 = 85:3kv]m pagal oa TT (Dp*— Ret) 24. = 23-64M wet forte on pees WAM (ener) = 1/- Len *. faction fore = 11 Ttan & Where 5 = 0-874’ = 28° +: fuotion fane = 6:2. bum. Ada frotion lubricant [sou i amrmns, at 0. 7 oem es ame foot 8 ar aay Shafi beast toted by avout 07. 10 anion for effects OF musaliguinent Ton froin = 62733 KAZ = Ith hnimPee, Pink: (oadeg - Faunce 8 Adlon for packer oF (Sum Fasc chupetoaave Or MOE, Gf wsittn WOmm. nomad design tend, WHEN BATON gen SONS AID SE. fre fm myermain avimun Pipe jacking toad amguisn alytection O-8° = SOT (4 400kN) - Distance to fist: inter gack © HOO — 1626 = 43m. Plas 51 HO Heong Protionsd load on vemaunung pipe pp longer ee Gos 248) Pipes) Smee one unteypck wit be mezded, better 10 tite, He healer Yo co repeated leading In pyres. coke th the bateycle cat F placed. after (com, inte yore ead = 4aqe t (106-5) W42s 2709KN (276T) and toad on On marie JACKS = 200 x W-y. = 2280KN~ (232T) ~ Tr el ae a eee terI 9.0 Worked examples Summary of Scheme B Tunnel face pressure Stury pressure to equal face pressure = 36 tonnes Tunnel face load Friction on the shield (4 metres) and the first few pipes (5 metres) where pipeline lubrication is not fully effective = 110 tonnes Cutting edge resistance of the shield ~ 20 tonnes Tolal front end load is 110 + 36 + 20 = 166 tonnes Tunnel bore stal Use 60KPa siurry pressure (0.5 bar) Ground closure With adequate slurry pressure maintained an overbreak of 20mm is sufficient. Ground settlement Provided adequale face pressute is maintained settlement should be negligible Long term settlement is calculated at 16.8mrn with a trough width of 9.5meties Pipe friction ‘otal friction from the lubricant/soll annulus, allowing 20% increase for any misalignment. is calculated at 1.16 tonnes/m Pipe joint loading Using a chipboard packer 120mm wide, and allowing a maximum angular joint de'lection of 0.52, the maximum pipe load is 450 tonnes From the estimation of pipe friction only one intejack is cequired. I is suggested that this is placed aller 100m which will result in an interjack toad of 276 tonnes and a final main jack load of 232 tonnes. Using a factor of safety of 1.5, it 1s suggested, that the theust wall be designed to accommodate 675 tonnes.10.0 References Pipe Jacking Associ ion Publications ‘An Invodvction to Pipe Jacking & Microtunnling Design Concrete Pipes for Jacking Smaller Daratrs (Mcrotunne! ad Unrantorced Pipes (Reterence BS6011; Part 120) Poa Jacking - Research Resuts anc Recommendations Geoige Milgan & Paul Noms. Osterd Universily Dopariment of Engneonng Science Principal Legislation and Standards ‘Construction (Design and Managemen) Regulations 1994 Hath and Satey at Work ate. Act 1974 Managernent of Heath & Safety at Work Regulations 1982 [BSS911: 1989 Pat 120 Specification for einlorced jacking pipes wr Rabie nes [BS6164: 1980 Code ol Practice fo sae in tunneling inthe construction industy [BSE005; Par Il. 1980 Sewerage - Guide to planning and construction of sewers in turned BS8110" Pats 18 f 1985 Structa use of concrete (Code of practice for desig and corsiructon Other References ‘kinson, JM. and Mat, 9, (1983) "Soll mechanics aspects of sok ground tunneling." Ground Engsneeting, VoL 14, Nos (Crag. AN. (19855, Pipe Jacking: stte-othe-at review. Tectncal Note Na. 112, GAIA, London, Haslem, FE, (1986) "Pipe jacking foro2s: rom theory to practice. Proceedings of hastrucire, Renovation and Waste Corot Centenay Contoranos NW Association, nsttuon of CM Engineers, Mat, RJ. (1987) ‘Discussion on tunel lace procaures soft clay, Proceedings of ih Asian Regonat Gonlerence on Soil mechancs and Foundation Engineering Vol page 290 (1087) eee, (1082 ‘The behawour of jacked concrete pipes duing ste stallion. O. Phi snes, Unnesty of Onto (Oly, NLP and Now, BM, (1962) ‘Setlernant above tunnels in the Unde Kingdom - ther magaude and preckton. Proceedings Tunneling '82 Symposium (nstute of Mining and Metaxas. Loner) poy, 4. (1980) “The perlomance of jacked pipes,” D. Ph the 2, Unvesy of Ontord Swoud MA. (1971) “The behaviou of sand at low sess levels n the imple show apparatus” PHD ness, Unwexsty of Camondge rea. K, (1983) “Thecvetical sol mecharies.” John Wiley and Sons, Now York. Taczagh, en6 Rehan, FE. (1952) *Stwsees in 1k about cavites" Gootecnnique, Vol 3 page 57 - 90 (As extracted tom. Poulos, HG ane Baws, EH. (197%) laste solutons for sll and rack mechanics -Jotn Wiley ad Sena, New Yor,Angular deflection The angle between two consecutive ppes Annular space ‘The void created by the dilterence in diamneters between the shield and jacking pipes. Articulated head A shield of two sections where the front section can be dellected 10 steer the shield or cutting head. Backacter ‘Amecnanwal device fer excavation within an open shield Bentonite Annatural clay with theotropic properties which can be used as a lubsicant, Butt-end The term usee tor square end jacking ppes Closed shield A shield with a closed pressure chamnber or cutting head which does not allow direct access to the face. Cutter boom ‘A mechanical device for excavation within an open shield, Cutting head The arrangement at the leading end of the shield which cuts the soil face. Deviation The variation from line and level to that specstied Earth pressure balance The creation of pressure to couiter the movement ot so1 into the shield Earth Pressure Balance Machine (EPBM) ‘Aull face tunnel boring machine with balanced screw auger 10 control the face pressure, Eye (Pipe jack eye) A sealing device paced m the shalt walls of the thrust and reception pits 10 allow the shield and pipes to enter and exit without soil, water andi stutty flowing into the shaits.Face undisturbed soll minediately anead ot the shel Guide rails Steel oF tunber ras set lumi 1n the thrust pit to give directional control al the pipes to be jacked and for accurate location of the pipe joints, Hand shield ‘An open face shield for manual excavation. Hydraulic jacks High pressure ttydrauically operated jacks providing the power to move the pipeline Interjack pipes Two specially designed pipes used with the intermediate, jacking station, Intermediate jacking station A fabricated steel shield incorporating hydraulic jacks designed 10 operate belween the interjack pipes to provide additional thrust load as necessary Jacking frame ‘fabricated frame for lauriching the shield and pipes from the thrust pit Jacking pipe ‘A pppe designed specatically for jacking which has a flexible joint Jacking shield A fabricated steel the excavation is cared out either by hand or machine. !ncorporated within the shield are facilities to allow the shield to be adjusted to control line and evel Inger wathun wh Joint The flexible sealing and jomnting arrangement between wo pipes Leading Interjack Pipe ‘The cipe immediately ahead of, or attached to, the interjack shield, Lead pipe The leading prpe manutactured to Hil the rear of the jacking shield and over which the trailing end of the shield is fitted“ o Lubrication Injection of a fluid such as bentonte 1o reduce pipe skin ficlon whilst jacking Microtunnel Aremote control method of installing pipes using a fully guided microtunnelling machine. Open shield A shield which allows direct access fo the soil lace Overcut The uilierence between the outside dimensions cut by the shield or face excavation and the external diameter of the oi Packing Material placed between pipe joints to distribute the jacking load Power pack ‘An hydraulic pump unit feeding fiuids to activate the hydraulic jacks Pressure plate (Backspreader) A steel pressure plate or plates located between the rear end of the jacks and the thrust wall to backspread concentrated loading. Rebated joint Aterm used to de of the pipe wall scribe a joint which Is forrned within the thickness. Reception pit ‘A shall al the end of the jacked section of pipeline from which the Jacking shield is recovered Skin friction The resisting force cr led between the pipes and soil when the pipes are jacked fonward. Slurry Aterm used for clay-water muds which can be pumped. Slurry tunnel boring machine A shield which incorporates a counter-balanee slurry chamber. Steel banded joint ‘Aterm used to describe a joint forrned with a steel band to locate and join each pipe. Usually used with butt-ended pipes,Thrust pit A working shall al the beginning of the yacked ection ul pipeline, in which the specialist equipment is installed, and from which the Jacking operations are carried out Thrust ring A steel ning thai «s placed agannst the cross sectional area of the pipe to ensure thal the jacking forces are spread around the circumference of the pipe. Thrust wall A wall al the rear of the thrust pit designed 10 spread the reaction toads to the yround behind the thrust pit Trailing interjack pipe cd pipe mmediately behind the merjack station whch slides into the rear of the shield. The rece: Tunnel boring machine (TBM) A shield with a rotating cutting head. Working shafts Ag reception pits. eral term applie to the more specilic Gescnpuon of must or