An introduction to

pipe jacking
 The pipe jacking technique
The major applications for pipe jacking and microtunneling include new sewerage and drainage
construction, sewer replacement and lining, gas and water mains, oil pipelines, electricity and
telecommunications’ cable installation, and culverts. Special applications include the installa-
tion of rectangular or circular sections for pedestrian subways, road underpasses and bridge
abutments.

The technique can be used to negotiate obstacles such as motorways, railways, rivers, canals,
buildings and airfields in the path of pipe laying projects; to minimize the surface disruption
frequently associated with open cut pipe laying methods in urban areas; or simply to provide a
permanent underground tunnel construction.

Pipe jacking is primarily used as an alternative to open cut excavations or other tunneling meth-
ods. Significant lengths are attainable at larger diameters using mechanized techniques. Refer-
ence should be made to Tables 4c and 4d for specific recommendations.

Construction methods are available to cope with both cohesive and non-cohesive soils in dry or
water bearing conditions. Excavation techniques are also available for jacking through rock or
mixed ground conditions, including cobbles and boulders.

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Advantages and disadvantage: Trenchless method
Decreasing cost of surface repair
Decrease Time of project ( Trenchless method
is very faster than open trench)
Crossing under the river and other structures
Less interface with infrastructures
Less disturbance in Traffic
Increasing pollutions
Environmental advantages
Ability to work under water
More Safety
Earth moving is reduced to minimum
Construction work in all weather

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 Pipe jacking, generally referred to in the smaller diameters as microtunneling, 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 excava-
tion is taking place within the shield. The method provides a flexible, structural, watertight,
finished pipeline as the tunnel is excavated. There is no theoretical limit to the length of
individual pipe jacks although practical engineering considerations and economics may

impose restrictions. Drives of several

hundred meters either in a straight line or to
a radius or a series of radii are readily achiev-
able. A number of excavation systems are
available including manual, mechanical and
remote control. Pipes in the range 150mm to
3000mm, can be installed by employing the
appropriate system. Construction tolerances
are comparable with other tunneling meth-
ods, and the pipe jacking method generally
requires less overbreak than segmental
tunnels and provides ground support and
reduces potential ground movement.
Mechanical excavation methods are similar
to those employed in other forms of
tunneling. Shields, excavation and face
support can be provided for a wide variety of
ground conditions.

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In order to install a pipeline using this technique, thrust and reception pits are constructed,
usually at manhole positions. The dimensions and construction of a thrust pit vary according to
the specific requirements of any drive with economics being a key factor. Pit sizes will vary
according to the excavation methods employed, although these can be reduced if required by
special circumstances.

A thrust wall is constructed to provide a reaction against which to jack.

To ensure that the jacking forces are distributed around the circumference of a pipe being
jacked, a thrust ring is used to transfer the loads. The jacks are interconnected hydraulically to
ensure that the thrust from each is the same.

A reception pit of sufficient size for removal of the jacking shield is normally required at the
completed end of each drive. The initial alignment of the pipe jack is obtained by accurately
positioning guide rails within the thrust pit on which the pipes are laid. To maintain accuracy of
alignment during pipe jacking, it is necessary to use a steerable shield, which must be frequently
checked for line and level from a fixed reference.

For short or simple pipe jacks, these checks can be carried out using traditional surveying equip-
ment. Rapid excavation and remote control techniques require sophisticated electronic guid-
ance systems using a combination of lasers and screen based computer techniques.

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Safety Benefits
Pipe jacking is an inherently safer method of working than open trench construction or
traditional segmental tunneling. When considering the risks associated with deep,
large section, open excavations, Health and Safety Executive guidance suggests these
risks should be reduced “if appropriate using ‘trenchless’ technology to avoid the need
to excavate the trench in the first place”. Given gang size differences between the
techniques and the resulting reduction in man-hours, opportunities for accidents to
occur are less with pipe jacking. There is also significant reduction in the risk of injury
as a result of utility strikes and interface with the public.

Environmental Benefits
There are substantial environmental benefits to be gained by the use of pipe jacking
techniques when compared with the traditional open trench approach. Typically the
‘trenchless’ method will reduce the quantities of incoming and outgoing materials, with
a consequent reduction in tipping of spoil and quarrying of imported stone fill. This in
turn leads to reduced vehicle movements and subsequently less associated disruption.
In many cases use of pipe jacking techniques instead of open trenching will
contribute positively towards workplace safety, the interface with the general
public, and the local and wider environment.

Technical Benefits
Technical benefits associated with pipe jacking are:
Inherent strength of lining
Smooth internal finish giving good flow characteristics
No requirement for secondary lining
Considerably less joints than a segmental tunnel
Prevention of ground water ingress by use of pipes
with sealed flexible joints
Provision of invert channels in larger pipes to contain
the dry weather flow of a sewer in a combined system
Less risk of settlement
Minimal surface disruption
Minimal reinstatement
Reduced requirement for utilities diversions in urban areas

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Pipe Jacking Project of Kayson
Hamedan Sewerage Project by Pipe
Jacking Method
Client: Hamedan Province Water & Wastewa-
ter Company
Financed by: Islamic Development Bank
Location: Hamedan, Iran
Contract Period: 36 Months
Partner: Mushrif of Kuwait
Key Statistics
■ Reception & drive shafts: 64
■ Manholes: 64
■ 1200 mm diameter pipes: 5329 meters
■ 1400 mm diameter pipes: 1564 meters
■ Excavation: 60,000 cubic meters
■ Concrete: 8,000 cubic meters
■ Formwork: 12,000 square meters

Tehran, Khaje Abdullah Ave.

Client: Tehran Water & Wastewater Company
Ministry of Power
Financed by: Ministry of Power
Location: Tehran, Iran
Contract Period: 12 Months
Key Statistics
■ Drive shafts: 34
■ Manholes: 33
■ 1400 mm diameter pipes: 552 meters
■ 1600 mm diameter pipes: 2170 meters
■ 1800 mm diameter pipes: 1180meters
■ Excavation: 10,620 cubic meters
■ Concrete: 8,814 cubic meters
■ Formwork: 5,810 square meters

Tehran, Region 2, 5 and 9 of Tehran

Client: Tehran Water & Wastewater Company
Ministry of Power
Financed by: Ministry of Power
Location: Tehran, Iran
Contract Period: 20 Months
Key Statistics
■ Drive shafts: 39
■ Manholes: 39
■ 1600 mm diameter pipes: 4283 meters
■ 1800 mm diameter pipes: 612 meters
■ Excavation: 9,632 cubic meters
■ Concrete: 2,880 cubic meters
■ Formwork: 9,410 square meters

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Polymer Concrete Pipes
Polymer concrete is a high strength, corrosion resistant concrete product which is
created when thermosetting polyester resin is used to bond the highest quality of
quartz aggregates under strictly controlled temperature and moisture conditions.
The polyester resin, which acts as the bonding agent, after curing, gives the pipes the
additional positive properties of elasticity, fracture and corrosion resistance. No
water or cement is used in the manufacture of polymer concrete products. Polymer
concrete products are corrosion-resistant during usage for flows with a PH range of
1.0 to 12.0. The glass-reinforced-plastic (GRP) couplings are made to connect plain
end pipes quickly and easily and provide the added benefit of leak-proof joints, thus
making polymer concrete pipes the natural choice for use in demanding municipal
and industrial sewage management systems.

It should be pointed out that the object of establishing PCPMC Co. in Iran are as
follows:

a)Approach to Sustainable
Development in water
and wastewater industry of
Iran

b)Production of environ-
ment friendly and recyclable
pipes for wastewater
industries

c)Production of corrosion
resistant and durable
pipes f o r sewage
transportation

d)Improving Science and

Technology in the field of
Composites and polymer
Concrete Materials and
Products

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Design and construction methods
Prior to embarking on a detailed construc-
tion design and method analysis, the client’s
engineer will generally have ascertained the
basic design parameters to meet
the requirements of the scheme.
For a sewerage system these are likely to include:
■ Hydraulic requirements
■ Preferred route
■ Depth
■ Gradient
Following an assessment of engineering,
environmental and cost parameters, pipe
jack excavation method and shaft construc-
tion will also be governed by a number of
factors which include:
■ Ground conditions
■ Details of existing services and
underground structures
■ Location of manholes and working areas
■ Lengths required
■ Diameters of pipeline
■ Economics
Ground conditions will play a major role in
determining the type of shaft to be
constructed, the pipe jack excavation method
and any ground support systems to be used.
Each of these may have limitations in terms
of either the diameter or length of drive. The
interface between these variables, together
with physical considerations, such as the
location of manholes and the size of working
areas, will provide an optimum solution or
range of solutions which can then be
appraised on the basis of cost and value
engineering.

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 Telephone: (+9821) 88072501-9 / Fax: (+9821) 88072500
Email: [email protected] / Website: www.kayson-ir.com
Head Office Address: Iranzamin Bldg., 2288 Iranzamin Ave., Shahrak
Qods, Tehran 1465613763, Iran

Designed and published by Kayson company