JACKING PIPE BROCHURE

J a ck ing Produc t s

w w w . t r a c e y c o n c r e t e . c o m

Jacking Pipes lowered onto guide rails

ControlRoom

Services Drainage

Work Station(maybe piled)

Standard Jacking Pipes

Excavated spoil may be removed

by trolly or conveyor

First lead pipe may have

rebate to fit cutting head steel shield

Cutter head type may vary depending on project.

e.g. open hand shield cutter boom shield

backactor shield

ControlRoom

Main Jacks to push jacking

pipe and cutting head

Jacking Pipes lowered onto guide rails

Depth can vary

Railways

Rivers

FootpathServices

Buildings, Roads and Traffic

Tunnelling can continue with no disruption to above

Receiving Workstation

Line of pipeline to be excavated

Cutting head, type can vary, as can method of removing excavated spoil through pipe to

ground level

First lead pipe may vary depending on cutting head

used

StandardJacking pipe

Lubrication pipe, if required, usually every 3rd to 5th

standard pipe

Interjack station, if required, consist of lead and trail pipe

with interjack station placed in centre

Work Station

E c o n o m i c B E n E f i t s

• Reduced levels of re-instatement• Lower maintenance costs

• Speed of installation• Construction work does not depend on the weather

• High degree of reliability and cost effectiveness• No requirement for secondary lining

A D V A n t A G E s o f J A c k i n G P i P E s

Tracey Concrete manufacture a comprehensive range of high quality Jacking Products to suit the requirements of the latest generation of pipe jacking systems. Jacking pipe tunnelling is a cost effective alternative to deep open cut pipe laying trenches which may not be practical due to the major disruption associated with open cut excavations, especially in urban areas. Tracey Concrete have a long tradition of producing high quality concrete pipes and our Quality Systems are recognised internationally.

i n t r o D u c t i o n

P A G E 2 | t r A c E Y c o n c r E t E

E n V i r o n m E n t A l B E n E f i t s

• Minimum excavation• Reduced noise, dust & dirt• Reduced risk of settlement

• Reduced disruption to surrounding areas• Less spoil

• 90% less vehicle movements

t r A c E Y c o n c r E t E | P A G E 3

P r o D u c t r A n G E

s t A n D A r D J A c k i n G P i P E sTracey Concrete Jacking Pipes incorporate the tried and tested butt end joint system with cast in steel band. Tracey Concrete Jacking Pipes are manufactured in accordance with BS EN 1916 and BS5911-1, BSI Kitemark certification.The butt ends joint design enables jacking forces to be transmitted over the maximum concrete area of the pipe hence reducing possibility of damage due to jacking loads. A compressible packing must be used to ensure even distribution of the jacking loads. The cast-in mild steel collar ensures no lateral displacement of the pipe during jacking. Stainless steel collars can be supplied on request.

D E s i G n D A t A

s P E c i f i c A t i o nThe Jacking Pipes are designed and manufactured to meet the requirements of BS 5911-1:2002 - Specification for unreinforced and reinforced concrete pipes (including jacking pipes) and fittings with flexible joints.

B s i k i t E m A r kBSI Kitemark Licence Number - KM 12296

tQ u A l i t Y m A n A G E m E n To BS EN ISO 9001:2008

m A t E r i A l sConcrete 28 Day Strength: 60 N/mm2

Cement: CEM II/A-VAggregates: To BS 882Reinforcement to BS 4482Joint Bands: From mild steel complying with BS EN 10025; Welding to BS 5135Seals: 2 Fin Elastomeric Seal in EPDM to BS 2492Grout Plugs: 1.25” BSP sockets

A Øc Ø

B

A DN: Inside diameter of pipe 600 900 1200 1500 1800 2040B Wall Thickness 80 80 100 115 145 140 160 180C External Diameter 760 760 1100 1430 1490 1780 2120 2400D Effective Length 1200 2000 2500 2500 2500 2500 2500 2500E Overall Length 1290 2090 2600 2600 2600 2630 2630 2650F Approx Weight/pipe (kg) 520 940 2200 3220 3660 4360 6020 8400G Max Jacking Force (Tonnes) 250 250 450 700 990 1100 1600 1800H Works Proof Load 48 48 72 97 110 121 145 164I Max Load (kN/m) 72 72 108 144 160 180 216 245


Lubricant pumped into small space

Lubricating pipe Standard Jack pipe

Grout Hose

Standard Jack pipe Lubricating pipe

Hyd and other hoses, not shown

for clarity

f i r s t l E A D P i P EPlaced at the front of usually shorter tunnel drives to locate the various cutter shield used which will be made to fit over the rebate on pipe.

first lEAD PiPE

i n t E r m E D i A t E J A c k i n G s t A t i o n s ( i n t E r J A c k s )

P r o D u c t r A n G E

An Intermediate Jacking Station is a fabricated steel cylinder fitted with hydraulic jacks that are installed temporarily into the pipeline between two Interjack pipes ~ trail Pipe & lead Pipe

Interjacks are commonly used on drives were jacking forces exceed the maximum that the pipes or jacks are capable of. Interjacks reduce the forces by pushing the pipes in front of the interjack first which means the main jacks are only required to push the rear section of pipes.

lead pipe long steel shield to fit over rebate on trail pipe.

interjack supplied and assembled by contractor

in closed position into lead pipe when introducing

pipes into tunnel

trail pipe long rebate and two rubber gaskets at end

trust rings

cylindersextend and

retract

hydpipes

hydcylinders

trail Pipe

lead Pipe

i n t E r m E D i A t E J A c k i n G s t A t i o n A r r A n G E m E n t

l u B r i c A t i o n P i P E sLubrication pipes look like a standard jacking pipe but have lubricating grout sockets cast into the pipe, at customers request. This lubricating grout socket is normally 1 ¼” BSP steel sockets fitted with plugs. Non-return valves are supplied as standard.

The ratio of lubrication pipe to standard jacking pipe will vary depending on ground conditions.

Tracey Concrete Jacking Pipes are manufactured with coloured steel bands so as to ensure ease of identification on site:• Lubrication Pipes - Yellow steel band• Standard Pipes - Blue steel band

lubrication sockets location(unless otherwise requested)

lubrication socket

lubrication socket

luBricAtion PiPE

i n t E r J A c k t r A i l A n D l E A D P i P E D E t A i l s

interjack trail pipe are as corresponding standard jacking pipe except for long

rebate and double seal on different spigot.

NOTE: With certain cutting shields can also be sold separately as the first lead pipe

Drive Direction

Joint Details as per corresponding diameter of standard jacking pipe

The Contractor assembles the hydraulic interjack station, into steel shield of lead pipe, before

trail pipe is introduced to fit into lead pipe

Joint Details as per corresponding

diameter of standard jacking pipe

E - As std pipe overall length

E - As std pipe overall length

D

A

A

Steel SheildSteel ring welded to

Sheild

lEAD PiPE(interjack)

1400

Rebate 1500

Rebate depthto suit seal joint

14001600

Steel Band

See joint detail below

B

trAil PiPE(interjack)


t Y P i c A l t r A i l A n D l E A D P i P E J o i n t D E t A i l

Long Rebate

Lubricantis filled

between seals

seal width, varies with pipe diameter between 45 and 60 long steel shield

SWSW

60 25

(spigot)

Separate MDF packer(for load distribution)

steel ring

spigot of trail pipe will slide back and forward as interjack engages and

releases

typical shape of rubber seal

before after compression

trAil PiPE lEAD PiPE

SW =

rubber seals

The Non-Integrated Seals, available from Tracey Concrete Ltd, are designed as a sliding seal. The special design on the joint and seal make the system easy to use during jointing.The seal is compressed when the pipe spigot is inserted into the socket, creating a positive seal under both internal and external pressure.The special design gives:

* low assembly force* excellent sealing capability under both internal and external pressure* good distribution of transverse shear load

To provide a safe and efficient means of lifting Jacking Pipes they are supplied with suitably designed cast-in lifting anchors as specified

Pipes should be lifted using a two legged chain with universal lifting eyes and two shortening clutches for altering chain lengths to ensure vertical loading of lifting anchor. Under no circumstances should the lifting system be used to lift more than one pipe at a time or to aid the jointing of pipes. Ensure that the crane hoist is centrally placed between the two anchors and lift the pipe. Lifting should be carried out slowly and steadily, avoiding all shocks and impacts. After lifting of the pipe the lifting eye should be removed and the lifting hole filled

Where stacking is necessary, this must be on level ground and the bottom layer of pipes securely chocked to prevent pipes from rolling or stack from collapsing. For safety reasons, pipes should not be stacked in layers higher than 2.0m. It is important to store rubber seals away from strong sunlight and frost.

Typical rubber seal before compressed

J o i n t i n G D E t A i l s

H A n D l i n G

l i f t i n G

s t o r A G E

PiPE sizE iD liftinG AncHors

DN 900 2 No. RD20 DN 1200 2 No. RD24DN 1500 2 No. RD30DN 1800 2 No. RD36DN 2040 2 No. RD36


J o i n t i n s t r u c t i o n s1 . Stretch the seal onto the pipe spigot and position

against the shoulder as shown. Equalize the tension by lifting and releasing the seal at

several points

2 . Apply forsheda lubricant on the socket. This must be evenly spread over the surface of the entire socket.

3 . Advance the pipe so that the rubber seal is in uniform contact with the edge of the steel collar of the pipe with which it is be jointed

4 . Centre the spigot into the socket and assemble

Rubber seal

Packer

15 to 60


P r o d u c t s a l s o a v a i l a b l e f r o m

tr a c e y c o n c r e t e i n c l u d e :

s p i g o t & s o c k e t p i p e s

m a n h o l e r i n g s & c o v e r s l a b s

P r e f o r m e d b a s e s

c a t c h p i t s

P l e a s e v i s i t


f o r f u r t h e r d e t a i l s

a n d f u l l r a n g e o f p r o d u c t s


Enniskillen, Co. Fermanagh, Northern IrelandTel: +44(0)28 6632 6437 Fax:+44(0)28 6632 4908

Email: [email protected]

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JACKING PIPE BROCHURE