microtunneling pipe

Microtunneling Pipe

QUOTATIONS DECAST Ltd. product prices and additional information can be found on our website at www.decastltd.com.

DECAST will provide quotations for projects on request. DECAST quotations include all products and services that DECAST can provide for a particular project.

To request a quotation, contact our sales team or email [email protected].

Please provide details of the project and drawings or direct us to the source of the details and drawings.

PRODUCT RELEASE AND DELIVERY

Once an order is placed with DECAST Ltd., it is entered into our production system. When customers are ready to receive product, they must call the DECAST Shipping Department to release materials for shipment. At that time, customers can let the shipper know when they would like product delivered and in what order they would like to receive product.

Customers will be advised of the estimated date and time of their delivery. Products are delivered to the job site on DECAST Ltd. trucks.

CONTACT SALES

416.605.7374 Rob Micieli Vice President, Sales

705.715.1269 David Archer, P.Eng.Marketing Manager

647.500.3789 Mauro DeFranco, P.Eng.Technical Sales Engineer

416.520.2779 Frank Mazza, C.E.T. Sales

905.302.1062 John Pozzobon, C.E.T. Sales

705.796.8868 Martin Fischer Sales

Benoit Tanguay, ing, P.Eng. 514.209.3188(Eastern Canada)

SALES [email protected]

ENGINEERING [email protected]

INFO & INQUIRIES [email protected]

DECAST Ltd.8807 County Road 56Utopia, ON L0M 1T01.800.461.5632705.734.2892

Engineering Fax: 705.734.2270Shipping Fax: 705.734.9373

WEB www.decastltd.com

The DECAST Ltd. manufacturing facility and head office is located in Essa Township just over an hour’s dirve north of Toronto, and a 10 minute drive west of Barrie.

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www.decastltd.com | Microtunneling | 3

Microtunneling is non manned, laser guided remote controlled, continuous pipe jacking. Pipes are jacked (pushed) in sequence from entry shaft to exit shaft.

In the words of the Pipe Jacking Association:

“Pipe jacking is a technique for installing underground pipelines, ducts and culverts. Powerful hydraulic jacks are used to push specially designed pipes through the ground behind a shield at the same time as excavation is taking place with the shield. The term Microtunneling is used for the diameters 0.45 m to 1.0 m ” (www.pipejacking.org)

Microtunneling is a trenchless construction method. It is used to install pipelines beneath highways, railroads, airport runways, harbours, rivers and environmentally sensitive areas without disturbance to the soils or surface above.

Microtunneling is different from open-shield pipe jacking in that continuous support is supplied to the excavation face to balance groundwater and earth pressures. Since its first use several years ago in Ontario, DECAST Microtunneling pipe has been installed under the 400 series highways, under railway tracks, beneath an airport, under a lake bed and below numerous busy urban streets.

With advancements in equipment and construction processes, Microtunneling is not limited to small diameters anymore. It can be used in numerous applications with reinforced concrete pipe diameters up to 3000 mm.

Microtunneling

Applications for Microtunneling

Direct pipe install for sewage and combined sewer overflow (CSO) systems, sewer outfalls, stormwater

Container pipes for pressurized water transmission lines, fuel lines, electrical and communication utilities

Pipe replacement

Microtunneling can be used in: Tight underground spaces crowded with other

services Areas of contaminated soils High groundwater areas Most soil types

4 | Microtunneling | www.decastltd.com

Specifying Microtunneling pipe with the ability to withstand the required jacking forces during installation and with the right properties for final product performance is as important as the choice of machine to install the pipe. Due to strength, stiffness and tight manufacturing tolerances, DECAST reinforced concrete Microtunneling pipes are suitable for long drives and for curved drives.

Since the introduction of DECAST microtunneling pipe in 2012 in Ontario, more than 25 kilometres of pipe has been installed.

4 Jacking Direction 4

DECAST Microtunneling pipe includes a butt end joint with a cast-in epoxy coated steel band. The butt end joint design allows the jacking forces to be transmitted over the maximum concrete area of the pipe.

A compressible packer is recommended to ensure even distribution of the jacking loads. The cast-in epoxy coat-ed steel collar ensures that there is no lateral displace-ment of the pipe during the jacking process. Stainless steel collars can be supplied on request.

DECAST Reinforced Concrete Microtunneling Pipe

Benefits of Microtunneling with Reinforced Concrete Microtunneling Pipe

Environmental No dirt, noise, smell or vibration Minimizes spoil Minimizes quarried material No harm to vegetation No dewatering required Minimizes truck traffic Low carbon footprint Small jobsite footprint

Safety No personnel inside tunnel during installation Less risk of ground settlement Minimizes interaction with people and traffic

Economic Less risk of ground settlement Installation is independent of weather

conditions Reduced disruption of existing underground services

No removal or treatment of contaminated soils No dewatering required

No secondary lining required in direct pipe installs

Minimizes removal of tunnel spoils


Pipes that are jacked (pushed) are subjected to both jacking forces and external earth loads. Both of these types of loads need to be considered in the design of the pipe.

The high compressive strength of concrete resists the jacking forces on the pipe barrel, however the primary factor in design of the pipe is the transfer of the jacking forces to the joint.

The forces must be resisted over a smaller cross-sectional area in the joint than in the pipe barrel. Coupled with that is the added complexity of jacking pipes in changing geological conditions underground. Jacking of pipes in straight lines is not practical and therefore jacking forces are often transferred eccentrically across the joint.

Standard Sizes For Reinforced Concrete Microtunneling Pipe

DECAST Ltd. Pipe Specification

Nominal Diameter

(mm)

Internal Diameter

(mm)

Wall Thickness

(mm)

Outside Diameter

(mm)

Effective Pipe Length (mm)

Pipe Weight

(kg)

Permissible Jacking Load

(tonnes) *

750 762 108 978 2400 1807 300

800 800 110 1020 2400 1925 350

DECAST-MT-750-108

DECAST-MT-800-110

DECAST-MT-900-121 900 914 121 1156 2400 2408 425

1000 1000 125 1250 2400 2704 500

1200 1200 115 1430 2477 3001 525

1200 1200 145 1490 2477 3870 650

1500 1500 140 1780 2477 4556 775

1500 1500 160 1820 2477 5270 900

1800 1800 175 2150 3000 8306 1150

2000 2000 200 2400 3000 10575 1425

2250 2250 225 2700 3000 13383 1725

2500 2500 250 3000 3000 16523 2050

DECAST-MT-1000-125

DECAST-MT-1200-115

DECAST-MT-1200-145

DECAST-MT-1500-140

DECAST-MT-1500-160

DECAST-MT-1800-175

DECAST-MT-2000-200

DECAST-MT-2250-225

DECAST-MT-2500-250

DECAST-MT-3000-275 3000 3000 275 3550 3000 21645 2400

DECAST Reinforced Concrete Microtunneling Pipe

* Factored jacking loads

Other internal and external diameters to suit specific project requirements are available on request.


Lubrication Pipes

Lubrication pipes are identified by a black epoxy coated steel band. Lubrication pipes have a lubricating grout socket cast into the pipe at locations shown in the diagram below. The number of lubrication pipes used will vary depending on ground conditions and the choice of the contractor but generally a lubrication pipe is used every 4th or 5th pipe.

Lubrication Port Locations

Standard Pipe Connected to Lubrication Pipe with Hoses

Lubrication Pipe

Lubrication Pipe with ApparatusLubrication Pipes


Intermediate Jacking Station (Interjacks)

An intermediate jacking station is a fabricated steel cylinder fitted with hydraulic jacks. The intermediatejacking station is installed in the pipeline between two Interjack pipes the LEAD PIPE and the TRAIL PIPE.

Interjacks are used on drives in which jacking forces willexceed the maximum allowable jacking force on the pipes. Interjacks reduce the forces on the pipe by pushing the pipes in front of the interjack. This means the main jacks only need to push the rear section of pipes.

Consideration should be given for interjacks on drives of 100 m or more and they should be included in the planning process and manufactured ready for use in case they are required.

Hydraulic Jacks

Lead and Trail Pipe Separated

4 Jacking Direction 4

Lead and Trail Pipe Assembled

Interjack Pipe


Jointing Details

The most important aspects of design in a Microtunneling project are the allowable degree of joint deflection and the joint face geometry. Jointing details are uniquely determined by each Microtunneling project. The joint face must be square with the pipe barrel and must be fitted with a suitable packer material so that the jacking forces are evenly distributed across the joint.

An essential feature of Microtunneling pipe joints which is different from conventional reinforced concrete pipe bell and spigot joints is that the joint does not extend out of the main barrel of the pipe. The entire joint is contained within the normal pipe wall thickness.

Many special jacking joints have been developed to handle specific situations. Rubber gasketed ring joints are used wherever watertightness is required. In the majority of Microtunneling projects, DECAST has supplied rubber gasketed joints. The gasketed joint is specified with a pressure rating suitable for the magnitude of the jacking force and the required joint deflection

Stresses on Pipe Joints

During the Microtunneling pipe jacking operation it is necessary to ensure straight alignment of the jacked pipes with the tunnel axis. Straight alignment ensures uniform stress distribution of the jacking force and avoids stress concentrations in small areas of the joint. Compression rings (cushioning packers) made of plywood, MDF or other low modulus material should be placed between the pipe joints to evenly distribute the jacking force through the jacking frame to the pipe. The cushioning packers reduce load concentrations caused by non-uniform jacking forces.

Pipe joints for intermediate jacking stations (interjacks) have to be specially designed. Provision must be made for the joint gap to be developed without the joint coming out of alignment, and hydraulic jacks have to be accommodated within the edges of the pipe wall.


Long Microtunneling Drives

When pipes are jacked from the launch shaft, the jacking force increases with the length of the section jacked. The pipe being pushed from the launch shaft must push all of the pipes in front through the soil. If jacking were to continue from the launch shaft only in long drives, the pipe could be damaged. Interjacks are used to increase Microtunneling drive lengths. With the use of interjacks the drive length is governed by economics. Microtunnelling drives of several kilometres have been realized using one or more interjacks.

Microtunneling Drives

Curved Microtunneling Drives

Curved Microtunneling drives are sometimes necessary to avoid conflicts with utilities and structures underground. They may also be used when a sewer line or a water transmission line has to follow a particular path. Curves in Microtunneling can be both horizontal (right-left) and vertical (up-down). Turning curves puts uneven loads on the pipe barrel and pipe joints. The minimum radius that pipes of a certain diameter can turn in a Microtunneling drive is dependent on the jointing system. Special jointing systems can be designed by DECAST to suit specific requirements.

Jacking Forces

The resistance that has to be overcome in order to push pipes through the ground varies greatly from case to case. It depends on:

Length and outside diameter of the pipeline

Weight of the pipe Height of the overburden Ground conditions Load on the leading edge Continuous/non-continuous operation Lubrication between pipe and soil

Radius of Curve

Launch Shaft North Don Relief Sanitary Sewer

The design of reinforced concrete Microtunneling pipe is based on practical experience gained from multiple Microtunneling case studies. Pipe design is challenging due to the on-site variation in transfer of jacking forces to the pipe barrel and pipe joint. The experience of pipe specialists like DECAST who are familiar with microtunnellling can make a significant contribution to a project, especially if we are contacted at the earliest possible stage. The combined field experience of the contractor and the pipe designer/manufacturer has been shown to be the largest cost saver on any project, far outweighing any apparent savings from the use of under-designed equipment, pipe materials or lubrication systems.

Each Microtunneling project is unique due to geological conditions, contractor skill and the microtunnel boring machine. For consultation on joint deflections, minimum radius of curvatures and specific project requirements, contact the DECAST engineering team at [email protected].

Manufacturing and Quality Assurance

DECAST reinforced concrete Microtunneling pipes are manufactured inside under controlled conditions. Concrete mix designs are developed and a computerized batching system ensures consistency of production.

DECAST holds a prequalification certificate in accordance with the Plant Prequalification Program for the manufacture of reinforced concrete Microtunneling pipe of pipe classes

65-D, 110-D and 140-D in accordance with CSA 257.2. Dimensions of each piece of pipe are verified, pipes are load tested and pipe joints are hydrostatically tested for watertightness.

Take Advantage of DECAST's Experience

10 | Microtunnelling | www.decastltd.com

Manufactured 100% indoors.Under 100% controlled conditions.

Most extensive product line in the industry

PRESTRESSED CONCRETE CYLINDER PIPE AND FITTINGS

VALVE AND UTILITY CHAMBERS

STEEL PIPE AND FITTINGS

BRIDGE GIRDERS

DE-SPAN®

BRIDGE SUPERSTRUCTURE AND SUBSTRUCTURE

TUNNEL SEGMENTS

BOX CULVERTS

REINFORCED CONCRETE PIPE

MAINTENANCE HOLES & CATCH BASINS

INTEGRATED FRAME & COVER MH SYSTEM (IFC)

HEADWALLS

RAILWAY / SUBWAY TIES

CONTACT SALES

416.605.7374 Rob Micieli Vice President, Sales

705.715.1269 David Archer, P.Eng.Marketing Manager

647.500.3789 Mauro DeFranco, P.Eng.Technical Sales Engineer

416.520.2779 Frank Mazza, C.E.T. Sales

905.302.1062 John Pozzobon, C.E.T. Sales

705.796.8868 Martin Fischer Sales

Benoit Tanguay, ing, P.Eng. 514.209.3188(Eastern Canada)

SALES [email protected]

ENGINEERING [email protected]

INFO & INQUIRIES [email protected]

DECAST Ltd.8807 County Road 56Utopia, ON L0M 1T01.800.461.5632705.734.2892

Engineering Fax: 705.734.2270Shipping Fax: 705.734.9373

WEB www.decastltd.com

The DECAST Ltd. manufacturing facility and head office is located in Essa Township just over an hour’s dirve north of Toronto, and a 10 minute drive west of Barrie.

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microtunneling pipe

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