CPAA DESIGN MANUAL

Jacking Design
Guidelines

Concrete Pipe Association

of Australasia
Jacking Design
Guidelines

First edition 1990

Revised 2013

Concrete Pipe Association

of Australasia

1
 JACKING PIPE GUIDELINES

Contents

1. INTRODUCTION

2. SCOPE

3. JACKING PIPES
3.1 The forces involved
3.2 Barrel Design
3.3 Joint Design

4. THE JACKING FORCES

5. JOINT STRESSES AND DEFLECTIONS

6. THE PIPE JACKING TECHNIQUE

6.1 Development
6.2 The Jacking Pit
6.3 The Shield
6.4 The Jacking Operation
6.5 Excavation
6.6 Control of Operation
6.7 Safety

7. REFERENCES

2
 Fig. 1.1.
CONCRETE PIPE ASSOCIATION OF AUSTRALASIA
Since this construction method was first introduced in the
CTIONS USA at the end of last century the technique has become
generally accepted throughout the world and considerable
UE development of plant and procedures has taken place,
1. Introduction
particularly in the last two decades.

I nstallation by jacking is a technique applicable to pipes of concrete and other rigid ma-
terials. Its use has become increasingly common in locations where open trenches would
seriously interfere with existing installations or with the traffic.

The pipes are positioned one by one in a pit or pits excavated at intervals along the line, and
from here the pipes are driven through the ground by hydraulic jacks. The excavation is car-
ried out at the first pipe, which is equipped with a shield, and - from here the spoil is carried
back to the jacking pit for disposal. The procedure is shown diagrammatically in Fig. 1.1.

Since this construction method was first introduced in the USA at the end of last century the
technique has become generally accepted throughout the world and considerable develop-
ment of plant and procedures has taken place, particularly in the last two decades.

tralasia

3
 JACKING PIPE GUIDELINES

Concrete Pipe Association of Australasia

2. Scope 3. Jacking Pipes
P ipes have been jacked in diameters up to
2. SCOPE
4000
to 1800.
mm with the most common range 900
Short lengths of smaller diameters have
3.13.The Forces
JACKING PIPESInvolved

J
Pipes have been jacked in diameters up to 4000 mm with the acking pipes, as opposed to pipes laid in open
beenmost
jacked through
common rangeholes
900 tothat have
1800. been
Short either
lengths of smaller 3.1 The Forces Involved
predrilled or thrust
diameters bored,
have been or the
jacked pipes
through have
holes been
that have been
excavations, are subjected to both jacking forces
forcedeither predrilled
through the or thrust and
ground bored,
theorspoil
the pipes
removedhave beenand external earthasloads
Jacking pipes, opposed
andtoboth
pipesof
laid in open
these excavations,
have to
be are subjected
considered to
when both jacking
specifying forces
the and
pipes.external earth loads
with forced through the ground and the spoil removed with an
an auger. and both of these have to be considered when specifying
auger.
The desire in recent years to jack long lengths of The effect of the jacking force on the pipe barrel
the pipes.
800 The
and desire in recent
smaller has leadyearstotothe
jack development
long lengths ofof is mostly small on account of the high compres-
800 and
The effectof
sive strength of the
the jacking
concrete. forceThe on joint,
the pipe barrel is mostly
however,
very smaller
elaboratehas lead to the development
excavation, control and of jacking
very elaborate
small on account of the high compressive strength of the
excavation, control and jacking equipment with excavation, must be considered because the joint cross-section
equipment with excavation, spoil removal, grade concrete. The joint, however, must be considered because
spoil removal, grade and bearing control all performed by is smaller, as across-section
rule, than isthat of the
and remote
bearing control all performed by remote
control. the joint smaller, as barrel and the
a rule, than that of the
control. jacking force
barrel and is transferred
the jacking forceeccentrically
is transferred across the
eccentrically across
Locations where jacking is most commonly used is under joint.the joint.
Locations where jacking is most commonly used
roads, railways, waterways or developed areas where
is under roads,would
railways, The external
The externalearthearthload
loadon onthe barrelisisequal
the barrel equal to smaller
to or
excavation causewaterways or developed
major disruption.
areas where excavation would cause major disruption. or smaller
than than
the the
trench trench
load on aload
pipe on a
bedded pipe
in abedded
trench of same
Length of pipe strings jacked range up to at least 250 m and in a trench of same width as the excavation (i.e. of the
width as the excavation (i.e. the outside diameter
Length of pipe strings jacked range up to at
longer lengths are readily achievable, but most economical pipe plusdiameter
the outside a margin of for the
over-excavation).
pipe plus a margin for
least range
250 appears
m and longer
to be 100-120 m. lengths are readily over-excavation).
achievable with intermediate jacking stations, but The jacking method of installation, therefore, is very efficient
from an external
The jacking methodload of point of view since
installation, the external
therefore, is earth
most Jacking forcesrange
economical usuallyappears
range between 1.5 and m.
to be 100-120 4 MN but up
to 30 MN have been used. very efficient from an external load point of viewload on
load is smaller than both trench and embankment
Jacking forces usually range between 1200 and pipes of the same diameter under the same height of fill.
since the external earth load is smaller than both
7000Whilst
kN butjacking
up toin30,000
straightkN lines of even
have beengrade
used.is the most
trench and embankment load on pipes of the same
common, horizontal as well as vertical curves have also
Whilst jacking in straight lines of even grade is the diameter under the same height of fill.
been jacked.
most common, horizontal as well as vertical curves
have The
alsoground best suited for pipeline construction through
been jacked.
jacking consists of granular or cohesive soils. Quicksand
The ground best(peaty)
and swampy suitedground
for pipeline
is poorlyconstruction
suited as control of
line and
through gradeconsists
jacking is extremely difficult, and
of granular jacking through
or cohesive
soils.rock re- quires and
Quicksand special excavation
swampy equipment
(peaty) groundor the
is use of
explosives.
poorly suited as control of line and grade is ex-
tremely difficult, and jacking through rock requires Detail - Intermediate Jacking Station
special excavation equipment or the use of explosives.

Jacking Pit

Laser

Track Hydraulic Jacks Jacking Shield

Figure 1.1 Typical Jacking Arrangement

Fig. 1.1 Typical Jacking Arrangement

4
 Jacking
Jacking Design
Design Guidelines
Guidelines
CONCRETE PIPE ASSOCIATION OF AUSTRALASIA

3.2 Barrel Design

3.2 Barrel Design
3.2 Barrel Design
Experience has shown that it can be difficult to
Experience has shown that it can be difficult to control Minimum
control
rotation
rotation
Experience
of the
of the
haspipes
shown thatpipes
during canduring
it jacking
the
the jacking
be operation.
difficult toFor
control
this Minimum TestTest
LoadLoad
operation.
rotation of For
the this
pipesreason
during it
theis customary
jacking to
operation.specify
For this Minimum
(see
Test
(seeAustralian
Load
AustralianStandard
StandardAS 4058-1992)
reason it is customary to specify circular reinforcement for
reason
circular it is customary to specify
reinforcement for jacking pipes.
jacking pipes. circular reinforcement for (see Australian
AS/NZS Standard AS 4058-1992)
4058-2007)
jacking pipes.
The
The earth load We
earth load on the
We on the pipes
pipes isis calculated
calculatedfrom
fromthe
The
the earth
followingload We on
formula: the pipes is calculated from the Theminimum
The minimumtest
testload
load(T.L.)
(T.L.) required
required is:
is:
following formula: The minimum test load (T.L.) required is:
following formula:
We – CWe
twB
2
– 2cCt-B 2cCtB
- CtwB2 where where
We - CtwB2 - 2cCtB where T.L.
T.L.== W
Wee
BB is
is the
themaximum
maximum width
widthof the
of excavation
the excavation
T.L. = W
FF e
wB isis the
the unit
maximum
weight width
of theofsoil
theabove
excavation
the pipe F
ww isisthe the unit
unit weightofofthethe
weight soilsoil above
above the pipe
thevalues
pipe
c is the soil cohesion for which indicative are given
c c isisthe soil
the soil
in Table
cohesion for which indicative
cohesion for which indicative values
3.1
values
are given F Fisisaa factor
factor which
whichcancanbebe
assumed
assumedto to
Ct are in given
Table in
3.1 Table 3.1 F be
is between
a factor 2which
and 3 can be assumed
depending on the to
is the trench load coefficient graphed in Fig. 3.1 be between 2 and 3 depending on the
CCt
t is isthe thetrench
trench load
load coefficient
coefficientgraphed
graphed in Fig. 3.1 3.1
in Fig. bedegree
between 2 and 3 depending
of over-excavation, theon the
withwith the
degree of over-excavation,
degree
smaller of over-excavation,
value corresponding to with
the the
larger
smaller value corresponding to the larger
smaller value corresponding
space between the excavationtoand
thethe
larger
Type of Soil Values of C space between the excavation and the
Type
Typeof
ofSoil
Soil Values of c kPa
Values
kPa of C space
outsidebetween the excavation and the
of the pipes.
kPa outside of the pipes.
outside of the pipes.
CLAY SOFT 2
CLAY SOFT 2 (Refer clause 9.3.3 AS/NZS 3725-2007).
MEDIUM 15 (Refer clause 9.3.3 AS 3725-1989).
MEDIUM 15 (Refer clause 9.3.3 AS 3725-1989).
HARD 50
HARD 50
SAND LOOSE 0
SAND LOOSE 0
SILTY 5
SILTY 5
DENSE 15
DENSE 15
TOP SOIL SATURATED 5
TOP SOIL SATURATED 5
Table
Table3.1
3.1- -Soil
SoilCohesion
Cohesion(c)(C)
Table 3.1 - Soil Cohesion (C)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
5
Avg. Unit Weight (kN/m3)
Avg. Unit Weight (kN/m3) A
A - Saturated Clay 20 A
BA- -Wet
Saturated
Clay Clay 20
19
4
4 CB--Sandy
Wet Clay
Clay 19
18 B
DC--Clayey
Sandy Sand
Clay 18
17 B
ED- -Loose
Clayey Sand Material 17
CttCt

Granular 16 C
E - Loose Granular Material 16 C
ValuesofofC

D
3 D
Values

3
E
E

Natural Surface
2 Natural Surface
2
H
H
B
1 B
1
Values of H/B
Values of H/B
Figure
Figure 3.1 -- Trench
Trench LoadCoefficient
Coefficient(C(Ct)
Figure3.1
3.1 - TrenchLoad
Load Coefficient )
t(Ct)

5
 JACKING PIPE GUIDELINES
Concrete Pipe Association of Australasia
3.33.3 Joint Design
Joint Design
Packer
Many special jacking joints have been developed to cater
Many special
3.3forJoint jacking
Design
various joints Some
applications. have typical
been developed to cater
joints are shown in
for various
Fig. 3.2 applications. Some typical joints are shown in
Fig. 3.2special jacking joints have been developed to cater Packer
Many a)
for Normal
various flush joint pipesSome
applications. have typical
been successfully
joints are jacked
shownandin
Normal flush joint pipes have been successfully jacked and
Fig.are
3.2suitable for moderate jacking forces.
are suitable
A packer for
mustmoderate
be appliedjacking forces.
as shown in Fig. 3.2a. It extends
over the fulljointlength of the periphery, but because the contact
ANormal
packerflush
must be appliedpipes have been successfully
as shown in Fig. 3.2a.jacked and
It extends
are area is
suitable small
for in comparison
moderate jackingwith the
forces. wall thickness and the
overloadthe isfull lengthrelative
eccentric of thetoperiphery, but because
the cross-section the theis
joint Steel Locating Band
A packer
contact must
area be applied as shown in Fig. 3.2a. It extends
limited toisjacking
small inforces
comparison with the
of the order givenwall
in thickness
Table 3.2.
over the full length of the periphery, but because the contact
and These
the load is eccentric
values do not take relative to the cross-section
into consideration the
the influence
area is small in comparison with the wall thickness and the
jointofispacker
limitedthickness,
to jacking forces and
elasticity of the order
joint given in
deflection, Tableis
which
load is eccentric relative to the cross-section the joint is
3.2. dealt with in more detail in Section 6.
b) Steel Locating Band
limited to jacking forces of the order given in Table 3.2.
These
These valuesring
values
Rubber do not
do not take
jointstake into
areinto consideration
consideration
included the influence
the influence
where watertightness
of packer
of packer thickness,
thickness,
is essential elasticity
which elasticity
is mainly andand joint deflection,
joint deflection,
in sewer and access which
which is
tunnel
dealt with in more detail in Section 6. Packer
applications.
is dealt with in more Detailsdetail
incorporating
in Section concrete
6. sockets as well
as stainless steel socket-sleeves have been used. (See Fig.
Rubber
Rubber ring joints
ring
3.2c-e). joints are
are included
included where
where watertightness
watertightness
is essential which is mainly
is essential which is mainly in sewer in sewer and access tunnel
tunnel Packer Packer
applications. Details
InfluencingDetails
applications. incorporating
these details are:
incorporating concrete
concrete socketswell
sockets as as
as stainless
i) The steel socket-sleeves
magnitude of the have
jacking been
force. used.
well as stainless steel socket-sleeves have been used. (See (See Fig.
ii)
3.2c-e).
Fig. The joint deflection required.
3.2c-e).
Both of these parameters depend on the degree of control c) Packer
exercised over details
Influencing these
Influencing these the operation,
details are: which again depends on the
are:
sophistication
i) i)The
Themagnitude
magnitudeof of the
oftheequipment
the jacking available.
jacking force.
force.
ii)ii)The
Thejoint
joint deflection
deflection required.
required. Rubber Ring
Both Theof ease
these with which tolerances
parameters depend onon theline and of
degree grade are
control
Both achieved
exercisedof these depends
overparameterson the squareness
depend
the operation, theof
onagain
which the ends
degree of the
of control
depends on the
pipes
exercised
sophisticationas well
over of as
thethe the equipment.
operation,
equipment which In this context reference
again depends on the
available.
should be made Steel Locating Band
sophistication of thetoequipment
the relevantavailable.
clauses on end squareness
in Australian Standard AS 4058-1992. Rubber Ring
The ease with which tolerances on line and grade are
The
achievedease depends
with which tolerances
on the on line
squareness andends
of the grade are
of the
achieved depends on the squareness of the
pipes as well as the equipment. In this context reference ends of the d)
pipes
shouldasbe well as the
Diameter
made equipment.
to the In this on
Max.
relevant clauses context
Jacking reference
Force
end squareness Steel Locating Band
should be made
in Australian Standardto the relevant
(mm) AS 4058-1992. clauses on end
(kN) squareness
in Australian Standard AS/NZS 4058-2007.
900 1200 Packer
Rubber Ring
1200
Diameter 1800 Force
Max. Jacking
Diameter (mm)
1500
(mm) Max. Jacking Force (kN)
2200
(kN)
1800
900 3100
1200 Packer
Steel Locating Band
2100 7000 Rubber Ring
1200 1800
1500 2200 e)
1800 3100 Steel Locating Band
2100 7000 Packer
* Refer to manufacturer for allowable jacking forces for different Confined Rubber Ring
joint configurations
Table 3.2 Maximum Jacking Forces Figure 3.2 Joints Suitable for Jacking Pipes
Fig. 3.2 Joints suitable for Jacking Pipes
Packer
Confined Rubber Ring
6
 CONCRETE PIPE ASSOCIATION OF AUSTRALASIA

4. The Jacking Forces 5. Joint Stresses and

Jacking Design Guidelines
Deflections
T he resistance which has to be overcome during
the jacking operation varies considerably from
case to case and only a range can be indicated. The
4. THE JACKING
influencing FORCES
factors are: T
5. JOINT
he theoretical line and grade of a jacked pipe-
line isSTRESSES
never completely achieved in practice.
AND DEFLECTIONS
Without making any allowance for margins to
1.
The Length
resistanceand outside
which has to diameter of during
be overcome jackedtheline
jacking Thecover variations
theoretical line andingrade
concrete strength,
of a jacked pipelinewhich
is never is
2. Weightvaries
operation of pipe
considerably from case to case and only a completely
irrelevant achieved
havinginregard
practice.
toToler Without making
the approximate any
nature
range
3. can beofindicated.
Height The influencing factors are
overburden allowance for margins to cover variations in concrete strength,
of this analysis, a uniform joint stress of around
4. Nature of ground which is irrelevant having regard to the approximate nature
1. Length and outside diameter of jacked line of 35/3 to 45/3
this analysis, MPa orjoint
a uniform 12 stress
to 15ofMPa can35/3
around be to
allowed
45/3
5. Load on
2. Weight shield or leading edge
of pipe MPaforormachine-made
12 to 15 MPa canand wet-cast
be allowed pipes
for cast respectively.
and spun pipes
6. Whether
3. Height operation is continuous or not
of overburden respectively.
7. Lubrication
4. Nature of ground Such deviations are corrected by adjustments which
5. Load on shield or leading edge result
Such in angular
deviations deflections
are corrected at the joints
by adjustments whichasresult
did the
in
When the operation
6. Whether jacking operation
is continuousis orstopped
not the resist- angular deflections
original at theprompting
deviations joints as did the
the original deviations
adjustments.
7. Lubrication
ance builds up very quickly in some soils. Jacking prompting the adjustments.
force increases of 20-50% are reported following In order to avoid damage to the joints due to over-
When the jacking operation is stopped the resistance builds In stressing
order to avoid damage
by the to the
jacking jointsitdue
force to importance
is of over- stressingto
delays of as little as 8 hours. Under such circum-
up very quickly in some soils. Jacking force increases of by the jacking force it is of importance to estimate the stress
stances pipe jacking should be of carried estimate the stress concentrations resulting from
20-50% are reported following delays as little out as a
as 8 hours. concentrations resulting from the angular joint deflections.
continuous operation whenever
Under such circumstances pipe jackingpossible.
should be carried out Asthe angular
a first joint deflections.
approximation it can be assumed that stress
as a continuous operation whenever possible. concentrations about 3 times the joint stress resulting from
The pipe jacking resistance per unit area of external As a first approximation it can be assumed that
completely uniform application of the jacking force must be
surface
The pipe ranges from 5 to
jacking resistance perover 40 kPa,
unit area and typical
of external surface stress concentrations about 3 times the joint stress
expected.
ranges from 5 to over 40 kPa, and typical values
values for various ground conditions are listed for various
in resulting from completely uniform application of
ground conditions are listed in Table 4.1. Without makingforce
the jacking any allowance
must be forexpected.
margins to cover variations
Table 4.1.
in concrete strength, which is irrelevant having regard to the
Without making
approximate nature ofany
thisallowance for margins
analysis, a uniform to cover
joint stress of
Ground Condition Jacking Resistance around 35/3 to 45/3 MPa or 12 to 15 MPa can be allowed
Ground Condition Jacking Resistance (kPa) variations in concrete strength, which is irrelevant
(kPa) for cast and spun pipes respectively. A more detailed analysis
having regard to the approximate nature of this
has been carried out by Lenz and Moller (Ref. 18) and the
Rock 2-3 analysis, a uniform jointonstress
following approach is based theirof around 35/3 to 45/3
development.
Boulder Clay 5-18 MPa or 12 to 15 MPa can be allowed for machine-
It made and wet-cast
is here assumed that the pipes respectively.
pipes are separated byAelastic
more
Firm Clay 5-20 packers
detailed analysis has been carried out with
of wood or hardboard. Materials a high
by Lenz and
Wet Clay 10-15 Poisson’s ratio like rubber and plastic are not suitable, as
Moller (Ref. 18) and the following approach is
they cause spalling of the joint edges.
Silt 5-20 based on their development.
Dry Loose Sand 25-45 It is here assumed that the pipes are separated by
Table 4.1 Jacking Resistance for Various Ground Conditions elastic packers of wood or hardboard. Materials
Having regard to the high static resistance, jacking capacity
with a high Poisson’s ratio like rubber and plastic
to cope with unscheduled stop- pages is necessary.
Having regard
In cohesive soil to the high static
a substantial portionresistance, jackingis
of the resistance are not suitable, as they cause spalling of the joint
capacity to copeandwith
ground adhesion, this unscheduled
can be reduced stoppages is
by lubrication. edges
The most commonly used lubricant is Bentonite, which is
necessary.
injected through nipples in
In cohesive soil a substantial portion of the resist-
the jacking
ance head and
is ground along theand
adhesion, pipethis
wall.can
It isbe
claimed that
reduced
lubrication repeated every 2-3 days can reduce the jacking
by lubrication. The most commonly used lubricant
force by more than 50% but average reductions of about
is
30%Bentonite, which is injected through nipples
are more common.
in the jacking head and along the pipe wall. It is
claimed that lubrication repeated every 2-3 days
can reduce the jacking force by more than 50%
but average reductions of about 30% are more
common.

7
 Concrete Pipe Association
JACKING of Australasia
PIPE GUIDELINES

Figure 5.2
Figure 5.2
The thickness of these packers before permanent
deformation is a´. Packer thickness after permanent
deformation, a = 0.6 a´.
L
Pipe length: L
φ
Total packer and pipe deformation can now be written:
Σ∆ a = ∆a + ∆L a ∆a
z packer
Where ∆ represents the dimensional change.
σjo
The deformations can be related to the stresses: max σ j
a L a L
σj E = σj E + σ E
j p c r r
t ri ri
where σ j is the stress in the joint and σ in the wall.

Ep and Ec are the corresponding elasticity coefficients,

and Ej an equivalent joint elasticity coefficient taking into
consideration pipe wall elasticity. In these expressions σ jo is the joint stress for uniform load.

tj From Fig 5.2 follows:

σ = σj ∆a
t
φ tg φ =
a a tj L z
hence: σj = σj + σj
Ej Ep t Ec a max σj
where: ∆a =
Ej
a t Ep Ec
and: Ej = a max σ j
a t Ec + Ltj. Ep hence: φ=
Ej z

The problem is now reduced to that of the stress distribution a σjo max σj σjo
or in radians: φ=
in an annular cross-section where the tensile stresses are Ej r z r
disregarded.
180 a σjo max σj σjo
and degrees: φ=
This case is treated in Ref. 12 and for the ratios of inner π Ej r z r
to outer radii of the joint ri r = 0.8, 0.9 and 1.0 curves
linking This equation allows us to estimate the safe deflection for
any pipe-joint configuration. It must be noted that this
max σ j σjo deflection is the combined pipe-packer deflection and is
max σ j σjo and are shown in Fig. 5.1.
z r larger than what would be measured at the joint.

If the deflection concentrated at the joint only is required

ri r = 0.8 ri r = 0.8
7 max σj the value of Ep should be substituted for Ej in the equation
σjo for φ.
6
ri r = 0.8
5 Above considerations are based on the simple elasticity
theory assuming that E is constant and independent of the
4
stress. This assumption is not valid for concrete, but it is
3 on the safe side. This explains why actual lines have been
deflected in excess of the safe angles predicted by above
2
considerations without causing any damage to the joints.
1
The following examples illustrate the advantage of wide
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
joints and thick packers on the permissible joint deflections.
max σj σjo
Figure 5.1
Figure 5.1 z r

8
 Jacking Design Guidelines
CONCRETE PIPE ASSOCIATION OF AUSTRALASIA

8750 x 103
Example 1. Packer (Joint) is full width of wall. Hence: σjo = = 16.7 MPa
(2000 +80)80 x π
Outside diameter: 2220 mm
max σ j 40.0
Inside diameter: 2000 mm and: = = 2.40 and from Fig 5.1
σjo 16.7
Wall and Joint Thickness: t = tj = 110 mm
max σ j σ jo
ri r = 0.90 = 1.5
z r
Jacking Force: 8750 kN
15 x 110 x 150 x 40000
max σ j = 40 MPa Ej = = 97.1 MPa
15 x 110 x 40000 + 3000 x 80 x 150
Ec = 40 000 MPa
Ep = 150 M Pa
15 x 16.7
Pipe Length, L = 3000 mm φ= o
x 1.5 = 0.00358 (Rad.) = 0 12’
97.1 x 1080
Compressed Packer Thickness, a = 15 mm
When comparing with Example 1 note the reduction in
8750 x 103 deflection angle caused by reduced joint width.
Hence: σj = = 12.0 MPa
(2000 + 110)110 x π
max σ j 40.0
and: = = 3.33 and from Fig 5.1
σjo 12.0 Example 3. This is identical to Example 2 with the
max σj σjo exception that the pipe length is halved. It then follows:
= 3.2
z r

15 x 110 x 150 x 40000 15 x 110 x 150 x 40000

Ej = = 85.7 MPa Ej =
15 x 110 x 40000 + 3000 x 110 x 150 = 117.9 MPa
15 x 110 x 40000 + 1500 x 80 x 150
15 x 12
φ= o
x 3.2 = 0.00606 (Rad.) = 0 20.8’
85.7 x 1110 5 x 16.7
φ= o
x 1.5 = 0.00295 (Rad.) = 0 10.1’
117.9 x 1080

For a 3000 mm length of pipeline with 2 joints the deflection

Example 2. Packer (Joint) is not full width of wall. o
would be 0 20.2’ or 68% greater than for the line with
Outside diameter: 2220 mm
3000 mm long pipes.
Inside diameter: 2000 mm
Wall, t = 110 mm
Joint, tj = 80 mm Example 4. This is identical to Example 3 except that the

1000 packer thickness is doubled.

ri r = = 0.93
1080 30 x 110 x 150 x 40000
Ej = = 132.0 MPa
Jacking Force: 8750 kN 30 x 110 x 40000 + 1500 x 80 x 150

max σ j = 40 MPa
30 x 16.7
Ec = 40 000 MPa φ= o
x 1.5 = 0.0053 (Rad.) = 0 18.1’
132.0 x 1080
Ep = 150 MPa
Pipe Length, L = 3000 mm Note that a doubling of packer thickness has increased the
Compressed Packer Thickness, a = 15 mm deflection by 80%.

9
 JACKING PIPE GUIDELINES

Concrete Pipe Association of Australasia

6. The Pipe Jacking 6.1 Development
Technique The preparation of a pipe jacking operation com-
mences with the excavation of the jacking pit -if
6.1
6. THEDevelopment
PIPE JACKING TECHNIQUE 6such is required.
.2 The JackingThe
Pitpit wall must be reinforced to
withstand the maximum jacking force envisaged.

T
6.1 he
Development
mechanisation in the last couple of decades, The preparation of a pipe jacking operation commences
“While
with it is relatively
the excavation of theeasy to pit
jacking design bearing
-if such ar-
is required.
and in later years the automation of pipe jack- eas,pitgrillages,
The mechanisation in the lastaims:
couple of decades, and in The wall must piles, or ground
be reinforced anchors
to withstand theto resist
maximum
ing has had the following Concrete Pipe Association of Australasia
later years the automation of pipe jacking has had the fol- jacking force envisaged.
the jacking loads, deflection can become a major
lowing
i) To aims:
reduce the labour content of the operation. problem. If insufficient rigidity is available, some of
i)ii)To To
reduce the labour content over
of thethe
operation. “While
the jack it iseffort
relatively
andeasyramto travel
design will
bearingbe areas,
lost ingrillages,
over-
increase the control operations. piles, or ground anchors to resist the jacking loads, deflec-
ii) To increase the control over the operations. coming become
elastic deformations. Deflections can cause
iii) To allow the jacking of pipes 800 mm and less tion 6can a major problem. If insufficient rigidity is
iii) To allow the 6.jacking
THE PIPEof pipes 800 mm
JACKING and less in diam-
TECHNIQUE .2 TheloadsJacking Pit jack
in diameters.
eters. available, some of the jack effort and or
eccentric to the base ramramtravelhead with
will be lost
6.1 Development subsequent
in overcoming
The seal
preparation failure,
elastic
of a pipe fracture
deformations.
jacking of the
Deflections
operation jack
can
commences body
cause
Reports of operations carried out 40 or more years eccentric
or bending loads
with the ofto
the theram.”
excavation ofjack
the base
(Ref or
jacking pitram
1). head
-if such with subse-
is required.
Reports of operations carried out 40 or more years ago refer
ago refer to advances
The per
mechanisation shift
in the around
last couple1.5
of m. To-
decades, and quent
in Theseal
pit wall mustfracture
failure, be reinforced
of to withstand
the jack body theormaximum
bending of
to advances per shift around 1.5 m. Today with a 3-4 man jacking force envisaged.
day with a laterman
3-4 years crew
the automation
of of pipe jacking
experienced men
crew of experienced men 2.5-5 m/shift are achieved on av-has Where
the
had the fol-
2.5-5 ram.” the (Refjacking
1). operation is under an embank-
lowing aims: ment a pitit isisrelatively
not required and bearing
the reaction may be
m/shift
erage arepeak
with achieved
reduce on
i) Toperformance average with
of content
the labour 10-15, peak
ofand
the perfor-
even higher
operation. “While easy to design areas, grillages,
outputs Where
taken the jacking
byoranchors operation
sunktointo is under
the an embankment
ground or deflec-
through a pit
mance for
of the
ii) smaller
10-15, anddiameters
To increase even higher
the control outputs
over the for the
operations. piles, ground anchors resist the jacking loads,
is not required
tion can and
become athe
majorreaction
problem. may
iii) To allow the jacking of pipes 800 mm and less in diam-rods anchored at the far side of the embankment. If be taken
insufficient by anchors
rigidity is
smaller diameters sunkavailable,
into thesome of theor
ground jack effort and
through rodsramanchored
travel will be
atlost
the far
Similarly layingeters.
tolerances have improved. Acceptable toler- Launching pad or guide rails are constructed al-
side in
ofovercoming
the elastic
embankment. deformations.
Launching Deflections
pad or can
guide cause
rails are
ance specifications
Similarly laying range from ±30-100
tolerances have mm in both
improved. vertical
Accept- eccentric loads tobe
theaccurately
jack base or ram head with subse-
Reports of operations carried out 40 or more lowing
years ago refer
constructed pipes to
allowing pipes to be aligned
accurately in direction
aligned in direc-
and
ablehorizontal
tolerance directions, and tolerances
specifications
to advances range
per shift around
actually
1.5from
achieved
±30-100
m. Today with a 3-4 man quent seal failure, fracture of the jack body or bending of
range from ±10-20 mm. andthe
tion grade.
and grade.
ram.” (Ref 1).
mm in both crew of experienced
vertical men 2.5-5 m/shift
and horizontal are achieved
directions, and on av-
The fact that the majority
erage with peak of performance
pipelines belong in the
of 10-15, andbelow
even higher
tolerances actually forachieved arange
strong from ±10-20
800
mm.
mm diameter range
outputs hassmaller
the beendiameters incentive to de- 6.3 The Shield
6.3 Where
The the jacking operation is under an embankment a pit
Shield
is not required and the reaction may be taken by anchors
velop suitable equipment for use in these diameters. Equip- sunk into the ground or through rods anchored at the far
Similarly laying tolerances have improved. Acceptable toler-
ment including sophisticated cutting heads, spoil disposal In
In well
side planned
well ofplanned andand
executed
the embankment. executedjacking
Launching operations
jacking
pad or guide railsthe
are lead
operations
The fact that ance specifications
the majority range
ofhas from
pipelines ±30-100 mm in
belong in theboth vertical
conveyors andand
steering devices resulted. pipe is equipped
constructed with
allowing a sharp
pipes to be edged shield
accurately
horizontal directions, and tolerances actually achievedthe lead pipe is equipped with a sharp edged shield alignedwhich
in serves
direc-
below 800 mm rangediameter
from ±10-20rangemm. has been a strong the two-fold purpose of reducing the resistance to the pipe
tion and grade.
which serves the two-fold purpose of reducing the
incentive toThe develop suitable
fact that the majorityequipment for inuse
of pipelines belong the belowentering the soil and minimizing the quantity of soil spilling
800 mm diameter range has been a strong incentive to de-resistance
into 6.3 ThetoShield
the pipe. Thethelatter
pipecanentering the enhanced
be further soil and minimiz-
by provid-
in these diameters. Equipment including sophisti-
velop suitable equipment for use in these diameters. Equip- ing
ing the
one or quantity
more of
bafflessoil
in spilling
the top into
segment the
of pipe.
the The
opening.
cated cutting heads, spoil disposal conveyors and
ment including sophisticated cutting heads, spoil disposal In well planned and executed jacking operations the lead
latter can be further
with enhanced byshield
providing one or
steering devices hasand
conveyors resulted.
steering devices has resulted. pipe is equipped a sharp edged which serves
Depending
more on the
thebaffles
two-fold in typetop
the
purpose ofofreducing
soil andthethe
segment ofpresence of pipe
the opening.
resistance to the ground-
water these’the
entering precautions may betheinadequate
soil and minimizing andspilling
quantity of soil chemical
Depending
stabilization, onThethe
freezing
into the pipe. type
and
latter can offurther
soil enhanced
compressed
be and
air atthe bypresence
the face of the
provid-
ing one or
excavation havemore allbaffles
been in the top
used segment unscheduled
to prevent of the opening.entry
of groundwater these precautions may be inad-
of soil
equate into the work
and onchemical area. stabilization, freezing
Depending the type of soil and the presence of ground-and
The shield may also
water these’ be equipped
precautions with individual jacks which
compressed air at the mayfacebeofinadequate and chemical
the excavation have
allowstabilization,
it to be tilted andand
freezing thereby making
compressed air atadjustment
the face of theto the
all been
direction used
of
excavation toallprevent
jacking.
have (See usedunscheduled
been Fig. 6.1). entryentry
to prevent unscheduled of soil
intoofthe work
soil into thearea.
work area.
The shield may also be equipped with individual jacks which
Theallow
shieldit to may also
be tilted and be equipped
thereby with individual
making adjustment to the
direction of jacking. (See Fig. 6.1).
jacks which allow it to be tilted and thereby making

Figure 6.1 Typical Jacking

Shield Arrangements

10 Fig 6.1 Typical Jacking Shield Arrangements

Fig 6.1 Typical Jacking Shield Arrangements
 CONCRETE PIPE ASSOCIATION OF AUSTRALASIA

6.4 The Jacking Operation 6.5 Excavation

When jacking short to medium lengths the jacking “Excavation equipment is selected on the basis
force is provided by jacks located at the pit and of job size, pipe size and type of ground. Normal
transferred to the pipe through a jacking head dis- method is to use short handled picks and shovels
tributing the load evenly along its periphery. plus miscellaneous pneumatic equipment, e.g. clay
spaders, jackpicks. In the very large jobs the ex-
“The jacks should all be of the one size and with a
pense of a ‘mole’ may be war- ranted. These gen-
total capacity well above estimated jacking loads.
erally have their own built in cutting and removal
While a stroke exceeding the pipe length will avoid
system.
the use of spacers it is usually uneconomical to pur-
Jacking DesignRemoval
chase jacks with strokes of this order. Short stroke
jacks although increasing the handling problems
Guidelines
of spoil is usually with

(1) a handcart
can reduce the size of the jacking pits. Jacks oper-
(2) conveyor belt
ate at a relatively high pressure – even the so-called
(3) small machines
low pressure jacks operate at 15 MPa. Jacking
6.4equipment
The Jacking shouldOperation
be clean and well maintained Removal of spoil is usually with
Handcarts are commonly used in the smaller pipes.
– particularly the hydraulic oil and filters. At least (1) a handcart
Providing the pipe slope is not severe and the pipe
(2) conveyor belt
When
onejacking shortshould
spare jack to medium lengths
be kept the jacking
on site. If one force
jack is kept
(3) reasonably clean quite heavy loads (1-2
small machines
is provided by jacks located at the pit and transferred to
fails the remaining jacks may have sufficient capac- tonnes) can be pushed. Small power winches assist
the pipe through a jacking head distributing the load evenly
ity its
along to periphery.
push the pipe -however, in most jack con- in adversearecircumstances.
Handcarts commonly used in the smaller pipes. Provid-
figurations the removal of one jack will apply an ing the pipe slope is not severe and the pipe is kept reason-
eccentric load to Conveyor
ably beltsheavy
clean quite are an
loadsexcellent means
(1-2 tonnes) canofbe trans-
pushed.
“The jacks should all the pipe.
be of the one size and with a total
capacity well above estimated jacking loads. While a stroke ferring
Small material.
power winches Asassist
the in
pipe-line is continually in-
adverse circumstances.
Although
exceeding thejacking rateswill
pipe length areavoid
relatively
the use slowof (e.g.
spacers0.3it creasing the conveyors must have quick means of
is usually uneconomical to purchase jacks with strokes to
m/hr.) power operated jacks should be used of Conveyor
adjustingbelts arelengths.”
flight an excellent means
(Ref 1). of transferring mate-
thisavoid
order.the Shortuneven
strokejacking and extra
jacks although labourthe
increasing associ-
han- rial. As the pipe-line is continually increasing the conveyors
dling
atedproblems can reduce
with manual the size
jacks”. (Refof1).
the jacking pits. Jacks Where
must havegroundwater
quick means of is adjusting
a seriousflight
problem com-
lengths.” (Ref
operate at a relatively high pressure – even the so-called 1).
pressed air has been used to counterbalance the
lowWhen
pressure jacking from only
jacks operate at 15oneMPa.position the jack-
Jacking equipment water pressure either by creating a compression
ing force
should be clean increases
and wellwith the length
maintained of the section
– particularly the hy- Where
chambergroundwater
immediately is a behind
serious problem compressed
the cutting face orair
draulic oil and filters. At least one spare jack
jacked. It is therefore usual when jacking long lines should be kept has been used to counterbalance the water pressure either
for smaller diameters by pressurizing the whole
on tosite.introduce
If one jackintermediate
fails the remaining jacks may have suf- by creating a compression chamber immediately behind
jacking stations where pipeline.
ficient capacity to push the pipe -however, in most jack con- the cutting Here also
face or foraugers
smaller or rotatingbycutting
diameters headsthe
pressurizing
the force is introduced between the pipes thus re- whole pipeline. Here also augers or rotating cuttingcut-
are used. In the latter case the pressure on the heads
figurations the removal of one jack will apply an eccentric
ducing the maximum force required. In this case ting
are head
used. may
In the be case
latter applied by the on
the pressure grout pressure
the cutting head
load to the pipe.
the rear pipe section acts as anchor for the reac- being
may be maintained
applied by the behind the head.
grout pressure being maintained be-
tion tojacking
Although the jacking force
rates are pressing
relatively the(e.g.
slow front
0.3section
m/hr.) hind the head.
forward.
power operated jacks should be used to avoid the uneven
jacking and extra labour associated with manual jacks”.
The
(Ref 1). pipe joints for such intermediate jacking sta-
tions will have to be specially designed as provision
Whenmust be made
jacking for both
from only a considerable
one position the jackingjoint
forcegap
in-
creases with the length of the section jacked.
to be developed without the joint coming out of It is there-
forealignment
usual whenandjacking long linesjacks
for hydraulic to introduce intermedi-
to be accommo-
atedated
jackingwithin
stations where
the edgestheofforce is introduced
the pipe wall. between
the pipes thus reducing the maximum force required. In this
caseInthe rearinstances
some pipe section acts
this as anchorhas
approach for been
the reaction
used toto
thethe
jacking force pressing the front section forward.
extent that all jacking except of the last 2-3
pipes to have entered the line is done from inter-
The pipe joints for such intermediate jacking stations will
mediate stations. The extreme in this development
have to be specially designed as provision must be made for
bothis to carry out jacking
a considerable at to
joint gap eachbe joint and to
developed limit the
without the
movement
joint coming outtoofone pipe at
alignment anda for
time. In thisjacks
hydraulic instance
to be
the jacking iswithin
accommodated donetheby edges
inflating rubber
of the tubes placed
pipe wall.
in the joints and by successive inflationtoand
In some instances this approach has been used the defla-
extent
thattion
all jacking
of the except
tubes aofworm-like
the last 2-3advance
pipes to is
have entered
achieved.
the line is done from inter- mediate stations. The extreme
in this development is to carry out jacking at each joint and
to limit the movement to one pipe at a time. In this instance 11 6.6 Control of Operation
the jacking is done by inflating rubber tubes placed in the
 JACKING PIPE GUIDELINES

6.6 Control of Operation A variation to (ii) has also been used in case of larger
Concrete Pipe Association of Australasia pipelines. Here a pilot line was first constructed near
Consistent control of direction and grade is essen- the invert and an accurate concrete cradle cast for
tial, a task which in recent years has been vastly the larger pipeline to slide on. An expensive but ef-
simplified by the use of laser beams. The level and fective way of ensuring close construction tolerances.
direction of the progress of the pipeline should be
Fig. 6.2 (b) shows the correction having been implemented 6.7
plotted
at in stage
an earlier order to allow
resulting earlymore
in a much adjustments as
accurate opera- 6.7Safety
Safety
instant correction to
tion than in Fig. 6.2 (a). direction of jacking cannot be Pipe jacking projects like all operations below ground re-
made. Pipe jacking projects like all operations below
quire careful attention to safety requirements. Poisonous
ground
gases require
whether careful by
generated attention to safety
the equipment require-
used or ema-
Fig. 6.2 (a) shows correction to the direction of ments.from
nating Poisonous gases whether
the soil excavated must begenerated
removed, by andthe
me-
jacking having
Corrections been
can be madedelayed until of
in a variety theways
pipeline has
as, for in- equipment
chanical used or
equipment mustemanating from the
be well screened soilregard
having exca-to
stance:
intersected the projected course. The result is that the cramped
vated must working conditions
be removed, andoften existing onequip-
mechanical projects
i)pipeline
By vertical and horizontal
overshoots in theadjustments of jacking force
opposite direction be- of this nature.
ment must be well screened having regard to the
position.
fore the corrective measures take effect. cramped working conditions often existing on pro-
ii) By excavating ahead to correct line and grade (cohesive Power requirements are ideally supplied by electricity or
soils
Fig. only).
6.2 (b) shows the correction having been im- jects of thisairnature.
compressed as internal combustion engines will require
iii) By adjustments to the shield. (Fig. 6.1) added ventilation and are very noisy in such a confined
plemented at an earlier stage resulting in a much Power requirements are ideally supplied by elec-
space. High pressure hydraulic hoses and connections must
more accurate
to (ii) operation than in in
Fig. 6.2of(a). tricity or compressed
A variation has also been used case larger pipe- be meticulously maintainedairandasindustrial
internal combustion
safety regulations
lines. Here a pilot line was first constructed near the invert
Corrections can be made in a variety of ways as, for engines will
governing therequire added
use of laser ventilation
must and In
be observed. aregeneral
very
and an accurate concrete cradle cast for the larger pipe- noisymining
local in such a confined
regulations must bespace.
followedHigh
withpressure
regard to
instance:
line to slide on. An expensive but effective way of ensuring plant and installations,
hydraulic hoses andand electric lighting
connections mustin be
most instanc-
meticu-
close construction tolerances. es needs to be limited to 32 volt.
i) By vertical and horizontal adjustments of lously maintained and industrial safety regulations
jacking force position. governing the use of laser must be observed. In
ii) By excavating ahead to correct line and grade general local mining regulations must be followed
(cohesive soils only). with regard to plant and installations, and electric
iii) By adjustments to the shield. (Fig. 6.1) lighting in most instances needs to be limited
to 32 volt.

A.
Start of Correction

Result of Correction

Deviation

Design Centre Line

Start of Correction

B. Result of Correction

Design Centre Line

Figure 6.2 Steering of Pipeline

12
Fig 6.2 Steering of Pipeline
 Jacking Design Guidelines
CONCRETE PIPE ASSOCIATION OF AUSTRALASIA

REFERENCES ENGLISH
REFERENCES 13.Horizontal Earth Boring and Pipe Jacking Manual.
14. Jacking Concrete Pipes.
National Utility Contractors Association, 1981.
AUSTRALIAN
AUSTRALIAN
CPA of Great Britain, Bull. No 5. 1980.
15. Pipe Jacking Basics. Civil Engineering, Sept 1979.
ENGLISH
1. Pipe Jacking – J Daffy. 16. How Intermediate Crowns extend Pipe Jacking
1. Pipe Jacking – J Daffy.
Cement and Concrete Association of Australia. Possibilities,
14.Jacking Concrete World Water, Feb 1980.
Pipes.
Cement and Concrete Association of Australia. Technical
Technical Note 24, 1973. 17.Pipe
CPA Jacking:
of Great A State-of-the-Art
Britain, Bull. No 5. 1980.Review.
Note 24, 1973.
2. Pipe Jacking and Boring in lieu of Tunnelling.
15.PipeConstruction Industry Research and Information
Jacking Basics.
2. Pipe Jacking and Boring in lieu of Tunnelling.
Proceedings of the 14th Conference of Engineers Association. Sept
Civil Engineering, Technical
1979.Note 112. 1983 by
Proceedings of the 14th Conference of Engineers control-
controlling Water Supply and Sewerage
16.How R NIntermediate
Craig. Crowns extend Pipe Jacking Possibili-
ling Water Supply and Sewerage Undertakings serving the
Undertakings serving the Cities and Towns of ties, World Water, Feb 1980.
Cities and Towns of Australia. Brisbane 22-26 Sept 1969.
Australia. Brisbane 22-26 Sept 1969. 17.Pipe Jacking: A State-of-the-Art Review.
3. Pipe Jacking in lieu of Tunnelling – R Surgener.
3. Pipe Jacking in lieu of Tunnelling – R Surgener.
Concrete Pipe Association of Australia (CPAA). National
Concrete Pipe Association of Australia (CPAA). GERMAN
Construction Industry Research and Information Associa-
tion. Technical Note 112. 1983 by R N Craig.
Seminar Melbourne and Sydney, Oct-Nov 1972.
National Seminar Melbourne and Sydney, 18. Lenz, D. undo Moller, H.J.:
4. Pipe Jacking – C Greeves. Hume News, Nov. 1971.
Oct-Nov 1972. Beispiele Fur im Durchpressverfahren Eingebaute
5. Pipe Jacking – G Magee. Hume News, Mar. 1972.
4. Pipe Jacking – C Greeves. Hume News, Nov. 1971. GERMAN Grosse Leitungen Aus Stahlbeton-und Spannbe-
6. A look at Horizontal Boring and Pipe Jacking – by Bill
5. Pipe Jacking – G Magee. Hume News, Mar. 1972. tonrohren. Betonund Stahlbetonbau 1970 NR.8.
Jones.
6. A look at Horizontal Boring and Pipe Jacking – by 18.
19. Lenz,
Lenz,D.D.:
undo Moller, H.J.:van Stahlbetonrohren
Durchpressen
Pipeline Construction, Aug-Sept. 1974.
Bill Jones. Pipeline Construction, Aug-Sept. 1974. Beispiele
SehrFur im Durchpressverfahren
Grossen Eingebaute Grosse
Durchmessers. Beton-und
7. The Jacking of a Concrete Pipe through Dry Running
7. The Jacking of a Concrete Pipe through Dry Run- Leitungen
Aus Stahlbeton-und
Fertigteil-Technik 1975 NR.9.Spannbetonrohren. Beton-
Sand, Dandenong Valley Authority,
ning Sand, Dandenong Valley Authority, und
20. Stahlbetonbau 1970 NR.8.
Scherle, M.: Technik und Anwendungsgrundsatze
Technical Report No.7, Oct 1978.
Technical Report No.7, Oct 1978. 19.
Lenz, D.:
des Rohrvortriebes. Baumaschine und Bautechnik.
AMERICAN Durchpressen
1971. van Stahlbetonrohren Sehr Grossen
Durchmessers.
21. Bielecki, R.: Maass, U.: Stein, D. Small diameter
AMERICAN
8. Concrete Pipe Lines. Beton-und
20.
jackedFertigteil-Technik
Scherle,
pipes: Development
M.:
from Hamburg
1975andNR.9.
experience
Pipes and Pipelines International.
American Concrete Pipe Association (ACPA) Publication
8. Concrete Pipe Lines. American Concrete Pipe
1942. Technik und
Aug. Anwendungsgrundsatze des Rohrvortriebes.
1983.
9. Concrete
Association
Pipe(ACPA) Publication
Handbook – ACPA 1942.
1980. Baumaschine und Bautechnik.1971.
9. ConcretePipe
10.Concrete Pipe Handbook
Design – ACPA
Manual 1980.
– ACPA 1970. 21. Bielecki, R.: Maass, U.: Stein, D.
10. Concrete
11.Design DataPipe
No.Design Manual
13 – ACPA – ACPA 1970.
1968. Small diameter jacked pipes: Development and experience
11 .Design
12.Marks: Data No.
Standard 13 – ACPA
Handbook for 1968.
Mechanical Engineers from Hamburg
12. Marks:
1978, SectionStandard
5, p.44. Handbook for Mechanical Pipes and Pipelines International. Aug. 1983.
Engineers 1978, Section 5, p.44.
13. Horizontal Earth Boring and Pipe Jacking Manual.
National Utility Contractors Association, 1981.

13
Concrete Pipe Association
of Australasia

www.cpaa.asn.au