AMIJACK GRP Jacking Pipe Systems. Excellent Solutions for trenchless Applications

Transcription

1 AMIJACK GRP Jacking Pipe Systems Excellent Solutions for trenchless Applications

2 Table of Contents 1 AMIANTIT AMIJACK Jacking Pipes Applications AMIJACK Pipe Manufacturing AMIJACK Design Quality Benefits Jacking Methods Microtunelling Pilot Pipe Jacking Product Range Pipes Couplings Jacking Pipes for Intermediate Stations Jacking Pipes with lubricant injection Nozzles AMIJACK GRP Pipes with Coupling Type GR AMIJACK GRP Pipes with Coupling Type SE AMIJACK GRP Pipes with Coupling Type SR and FJ Transport and Storage Technical Support...14 Appendix A - Questionnaire for static structural analysis for AMIJACK GRP pipes acc. to ATV A

3 1 AMIANTIT Group of Companies 2 AMIJACK Jacking Pipes The AMIANTIT Group is an internationally active organisation with a track record of growth-orientated success. Its mission is to supply pipe solutions for water, sewage, gas, oil and industrial applications as well as pipe technologies, water management services and building materials of superior quality and value to customers all over the world. The group is confidently looking forward to achieving its vision of global leadership. AMIANTIT Europe is based near Dresden in Germany and its management team coordinates all the manufacturing and sales activities of AMIANTIT in Europe. A multicultural management team with a shared vision guarantees the best support and customers are serviced by many local sales and manufacturing organisations within Europe. Based on extensive expertise, AMIANTIT Europe offers optimised pipe systems for many different applications. Depending on each customer s requirements AMIANTIT s three European manufacturing sites supply GRP (Glass fibre Reinforced Plastic) pipe systems branded as FLOWTITE, AMIREN and AMIJACK. AMIJACK jacking pipes are GRP pipes manufactured in a centrifugal casting process in high speed rotating moulds. They are made of polyester resin, glass fibre and silica sand. The pipes are designed for the construction and renovation of underground pipelines using trenchless methods. The pipes feature high ring stiffness and a coupling design in which the outer diameter is similar to the outer pipe diameter. The AMIJACK product range consists of the following products: Standard jacking pipes Jacking pipes with injection nozzles Jacking pipes for intermediate jacking stations Relining pipes Fittings based on AMIJACK pipes (elbows, T-pipes, branches, reducers, connectors for embedding, manholes) Special, tailored fittings Jacking technology is the major application for centrifugally cast GRP pipes. The AMIJACK pipe design offers outstanding product advantages, which are important in jacking technologies. It makes this pipe system the ideal solution for such projects and offers added value to customers at competitive prices. 2.1 Applications AMIJACK pipes are used in pipeline construction for the transport and storage of water, rainwater, sewage and industrial wastewater. The following trenchless techniques are used in AMIJACK pipe installation: Microtunneling with drilling and hydraulic or pneumatic spoil removal Hydraulic jacking with remote control drilling Burst lining Pipe eating AMIJACK pipes can be installed in straight or curved sections in vertical or horizontal positions. The construction methods are suitable for both cohesive and non-cohesive soils in dry conditions or high water table conditions. Excavation techniques are also available for jacking through rock, boulders or mixed ground conditions. Pipe jacking is primarily used for: Construction of new sewer pipelines Old sewer replacements 3

4 3 AMIJACK Pipe Manufacturing Construction of channels as protective tubes for gas pipelines, heating pipelines, etc. Road and technology culverts in transport engineering Electricity and telecommunication cable ducts in urban areas or areas with groundwater restrictions Relining The AMIJACK manufacturing process consists of the raw materials being fed into the rotating mould in specified amounts in order to form a layered composite structure with a compact construction. The raw materials are precisely metered by the special feeder which adds the various materials in accordance with the design formula of the pipe being produced. The pipes are made of the following basic raw materials: Polyester resin Chopped E or E-CR glass Silica sand additives After feeding all the raw materials, the rotating speed of the mould is increased. This ensures compaction of the pipe composition under pressures of up to 70 bar which results in an extremely smooth inside and outside surface on the pipe. The components are cross-linked as a result of heating the mould. This causes hardening of the material and provides the required mechanical properties. After curing, the pipe is removed from the mould and transported to the finishing area for cutting, machining and coupling assembly. 4

5 4 AMIJACK Design 5 Quality AMIJACK pipes Exterior Surface Chop Layer Outer Structural Layer Core Inner Structural Layer AMIJACK pipes meet all the criteria of the EN-ISO standard, thus ensuring excellent quality and precision of workmanship. AMIANTIT s quality system imposes specific procedures at every stage of pipe production from raw material control, through pipe production and ending with tests on the finished product. Ongoing quality control of finished products includes: Visual inspection and dimensional verification Determination of initial ring stiffness Chop Layer Barrier Layer Interior Layer The pipe manufacturing process using centrifugal casting creates a very compact composite structure, which is necessary and very important for jacking applications. The unique wall construction ensures the proper and safe use of pipes at the time of installation and during later operation. The centrifugal cast technology enables the production of a wide range of pipe wall thicknesses. This allows the optimal pipe selection in terms of the required ring stiffness and the maximum permissible jacking force required to assemble the given pipeline section. Determination of initial resistance to failure in deflection conditions Determination of axial compression strength Determination of initial modulus of elasticity in compression 5.1 Benefits The main benefits of pipe jacking compared to open trench method are: Minimum environmental disturbance, especially in urban areas, Significant reduction in social costs, A strong, watertight, complete pipeline after jacking is finished, Usually low installation costs compared to open trench technology, Pipe structure can be designed individually according to project-specific requirements. Compared to other materials, AMIJACK GRP pipe systems guarantee: High axial compressive strength (min. 90 N/mm 2 ). high maximum allowable jacking forces with small wall thickness Properties of the AMIJACK pipes Parameter Value low required wall thickness Smooth and even outer surface Specific weight of material 20 kn/m 3 Longitudinal compressive strength 90 MPa Safety factor for jacking force 3,5 minimum required jacking forces compared to other materials, low water adhesion (small friction during jacking), Colebrook-White coefficient Hoop flexural modulus Pressure 0,01 mm MPa Gravity; Pressure pipes on request low jacking effort, especially after breaks Max. single drive length up to 300m depending on soil conditions and jacking parameters 5

6 Elastic material behaviour consistent distribution of concentrated compressive stress (especially in curves) low risk of cracks Pipe can easily be machined ability to perform couplings or fittings after completion of jacking ability to build a manhole in a completed pipeline Low specific weight of GRP material reduced handling efforts high safety The excellent hydraulic characteristics of AMIJACK pipes allow a smaller wall thickness compared to pipes made of other material. This results in: smaller jacking machines minimum excavation volume reduced jacking forces maximum jacking length - max long single drive length up to 300m depending on soil conditions and jacking parameters smaller electric/hydraulic power units smaller starting pit (thrust block volume) lower energy consumption reduced construction time maximum cost savings optimal price-to-performance ratio Comparison of outer diameters of conventional and CC-GRP pipes Concrete wall thickness GRP wall thickness Concrete OD Concrete OD GRP GRP Figure 5-1 Comparison Concrete-GRP jacking 6

7 6 Jacking Methods 6.1 Microtunneling Trenchless pipeline construction using the microtunelling method involves using a drill head to tunnel, with the simultaneous installation of leader pipes. The construction of a pipeline using this technology takes place from the starting shaft to the target shaft. After establishing the starting shaft, a remote-controlled jacking head is placed at the bottom and pressed into the surrounding soil. The seal ring mounted on the chamber wall prevents ground water and soil from getting inside it. Jacking forces are generated by a hydraulic jacking station with powerful jacking cylinders and a pressure ring that pushes the drilling machine deep into the soil following the direction and slope of the target pipeline. In the next stage, the drilling head is pushed by jacking pipes which transfer pressure forces from the jacking station to the microtunnelling machine. Pipes are lowered to the bottom of the starting shaft and installed one by one behind the jacking machine. Soil is continuously excavated by a cutting tool mounted on a rotating disc and transported hydraulically through slurry lines to the surface of the site into a sedimentation tank. The water is separated from the soil and pumped back through supply pipes into the excavation and crushing chamber of the drill head. The hydraulic soil transport system operates as a closed loop and allows rapid progress of the pipeline construction work. Other methods for the excavation and transportation of soil include using mini excavators on the forehead, spiral conveyors or a shuttle train on the track. A gyro or laser guidance system ensures accurate targeting of the receiving shaft with the drill head. The drilling machine is controlled by an operator in a control container on the surface near the starting shaft. Numerous sensors and devices send all the data necessary for the operator to control the drilling head according to the planned pipeline axis. During drilling and pipe installation, the jacking force value is recorded, so as not to exceed the maximum allowable jacking force for the pipes. In order not to exceed the jacking forces during the installation of pipes over a long distance, mounted intermediate jacking stations push a specified length of the assembled pipeline. They are installed and pushed in a manner similar to the pipe jacking. In order to minimise installation costs, these stations are located, wherever possible, in areas where manholes are planned after completion of the pipeline. 7

8 6.2 Pilot Pipe Jacking The technology of jacking with pilot drilling involves constructing the pipeline in several stages between the starting shaft and the target shaft. In the starting shaft, a hydraulic jacking machine with the specified capacity is placed and adapted to the given range of pipe diameters being installed. STAGE I Pilot boring STAGE II Reaming boring and jacking of temporary pipes The first step is to perform a pilot boring using a pilot rod which is pushed into the soil, compacting it around the hole being formed. Drilling is carried out from the starting shaft to the target shaft with high accuracy, thanks to a tele-optic system inside the head and its location system. The second step is to drill the hole with a reamer or a multi-blade head mounted on the last pilot rod. The reamer is pushed into the ground using reusable steel pipes, which are installed behind it and at the same time it pushes out the pilot rod in the target shaft. Soil, transported through front holes in the reamer into the steel pipe, is conveyed to the starting shaft using a spiral conveyor moving inside the pipe. After the steel pipes reach the target shaft, the spiral conveyor is dismantled. The third stage involves pushing the temporary steel pipes into the target shaft by pressing the AMIJACK pipes into place. The pipeline construction is completed when the AMIJACK pipes reach the target shaft. STAGE III Pushing-in the AMIJACK CC-GRP jacking pipes 8

9 7 Product Range 7.1 Pipes The pipe product range for trenchless applications is classified according to the following parameters: Outer diameter (mm) Ring stiffness (N/m 2 ) GR coupling GRP sleeve made of polyester resin reinforced with fibreglass. The inner surface of the sleeve fits tightly to the wedge seal made of EPDM, SBR or NBR embedded into a special groove on the pipe spigot. The GR coupling is predominantly used for larger pipe diameters (DA 1000). Unit length AMIJACK GRP pipes are offered in standard lengths of 1, 2, 3 and 6 m. Other lengths are available on request. 7.2 Couplings AMIJACK GRP pipes are generally connected using couplings. A standard AMIJACK jacking pipe is equipped with a coupling pushed onto one of the spigots. Couplings for jacking pipes have an outer diameter equal to the outer diameter of the jacking pipes, so that the resulting connections do not interfere with the installation process. This coupling solution makes it possible to use AMIJACK pipes in trenchless applications. Depending on the intended use, couplings are available in different types, pipe diameters and pressure classes. The coupling seals are made of elastomeric materials and meet EN and ASTM F-477 standards. SR coupling sleeve of stainless, improved corrosionresistant steel. Similarly to the GR couplings, the inner surface of the sleeve fits tightly to the wedge seal made of EPDM, SBR or NBR embedded into a special groove on the pipe spigot. The SR coupling is mainly used for larger pipe diameters (DA 1000) and when higher permissible jacking force is required. FJ coupling the design of this coupling is adapted for pressure applications. The coupling is equipped with REKA seals, also used for connecting standard GRP pressure pipes installed in an open trench. This solution is proposed for pressure jacking applications not exceeding 6 bar. The suitability of the FJ coupling should always be discussed with the manufacturer. SE coupling stainless steel sleeve integrated with an elastomeric seal over the entire width. Several types of steel are available, adapted to the operating conditions. The seal is made of EPDM. However, SBR or NBR seals are available on special request. 9

10 7.3 Jacking Pipes for intermediate Stations Where the overall jacking length is too long and/ or the allowable jacking force is too small, so called intermediate stations are used, which are installed along with special jacking pipes (leader pipe and trailer pipe). These special jacking pipes allow reciprocal movements of the station, generated by ejecting hydraulic cylinders that are installed circumferentially between the two pressure rings. The intermediate station is schematically illustrated in Figure Steel cylinder Hydraulic Press Leader pipe Trailer Pipe Torsion Stiffness Steel Ring Injection valve for lubrication of rubber Wood Ring Rys. xxx Figure Intermediate jacking station 7.4 Jacking Pipes with lubricant injection Nozzles To reduce friction of the surrounding soil with the outer pipe surface during the jacking process, jacking pipes with injection nozzles are used. The nozzles are made of steel and compatible with a lubricant feeding system (usually bentonite). Normally, the nozzle comprises a sleeve, check valve and a plug. The nozzle diameter is mostly ¾ or 1. Usually, three or four holes are established every 90 or 120 in the middle of pipe length. Because of the assembly operations, lubrication nozzles are used in pipes with man-accessible diameters

11 11 d OD e Max. allowable jacking force F perm [kn] for SN [N/m 2 ] acc. to ISO with closed connection contact. Safety factor 3,5 SN SN SN SN SN SN SN SN SN SN SN SN e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm [mm] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] 427* * * * * * d OD 7.5 AMIJACK GRP Pipes with Coupling Type GR 1348* * * * * * Table Maximum allowable jacking forces Fperm [kn] depending on pipe stiffness SN [N/m 2 ] (*) diameters on request

12 12 d OD e Max. allowable jacking force F perm [kn] for SN [N/m 2 ] acc. to ISO with closed connection contact. Safety factor 3,5 SN SN SN SN SN SN SN SN SN SN SN SN e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm e F perm [mm] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] [mm] [kn] 427* * * d OD 7.6 AMIJACK GRP Pipes with Coupling Type SE 860* * * ,7 1348* , , ,0 Table Maximum allowable jacking forces Fperm [kn] depending on pipe stiffness SN [N/m 2 ] (*) diameters on request

13 7.7 AMIJACK GRP Pipes with Coupling Type SR and FJ 3. Steel ring coupling Steel Ring e e 4. FLOWTITE jacking coupling (low pressure applications) d OD dod Max. allowable jacking force F perm [kn] for SN [N/m 2 ] acc. to ISO with closed connection contact. Safety factor 3,5 dod [mm] SR steel ring coupling FJ FLOWTITE jacking coupling e [mm] F perm,p [kn] e [mm] F perm,p [kn] 427* * * * * * * * * * * * Table Maximum allowable jacking forces Fperm [kn] depending on pipe stiffness SN [N/m 2 ] (*) diameters on request 13

14 8 Transport and Storage 9 Technical Support AMIJACK GRP pipes are supplied to many countries around the world. Our logistics experts cooperate closely with the best transport companies to develop the best form of pipe transport directly to construction sites. Pipes are generally supplied by trucks as a single load or nested set. Pipe transport is also possible by sea and rail. The finished pipes are factory-equipped with couplings, seals, wooden spacers (if necessary), a defined amount of anti-adhesive agent and other details that are agreed with the customer at the bidding stage. The pipes need to be stored in a position and at conditions defined by the manufacturing site. Handling requires belts or plastic straps to be attached around the pipes. Engineers from the pipe manufacturer and supplier offer a wide range of services related to: technical advice in the investment planning phase, static structural analysis, hydraulic calculations, selection of the proper pipe parameters and raw materials, drawings and diagrams of pipes, manholes and fittings, technical advice for contractors during installation, solutions for special applications. 14

15 Appendix A Questionnaire for static structural analysis for AMIJACK GRP pipes acc. to ATV A161 Project name: Section no.: Design studio: Contact person: Telephone: JACKING PIPE DETAILS: Nominal diameter DN [mm]: Wall thickness e [mm]: Pipe unit length: 0 2 m 0 3 m 0 other...[m] LOADS: Soil cover over pipe top [m]: h max = [m] h min = [m] Ground water level above pipe bottom [m]: Traffic loads acc. to ATV A161 hw = [m] hw = [m] max min Truck loads: 0 LKW 12 0 SLW 30 0 SLW 60 Railway loads UIC-71: 0 single-track trail 0 multi-track trail Aircraft loads: 0 BFZ 90; 0 BFZ 180; 0 BFZ 350; 0 BFZ 550; 0 BFZ 750 Other loads (e.g. internal pressure, heaps, embankments, over-sized cargo transport etc.) JACKING CONDITIONS: Resistance to the drill head [kn] Outside diameter of drill head [mm] Lubrication during jacking 0 yes 0 no External pressure of lubricant [bar] DATA OF THE SEGMENT BEING JACKED: Straight segment: Curved segment: 0 Segment length [m] L = [m] 0 Curve length [m] L = [m] 0 Radius length [m] R = [m] SOIL CONDITIONS (native soil at jacking depth): Soil type acc. to ATV A127: 0 G1 0 G2 0 G3 0 G4 (non-cohesive soils) (clay non-cohesive soils) (sandy cohesive soils) (cohesive soils) Proctor density: D Pr = [%] Plasticity index: I L = [-] ATTACHMENTS: 0 Site plan 0 Longitudinal profi 0 Cross section 0 Geological documentation COMMENTS: Date: Signature: 15

16 Utmost care has been taken to ensure that all the contents of this brochure are accurate. However, AMIANTIT and its subsidiaries do not accept responsibility for any problems which may arise as a result of errors in this publication. Therefore customers should make inquiries into the potential product supplier and convince themselves of the suitability of any products supplied or manufactured by AMIANTIT and/or its subsidiaries before using them. Distributed by: RPC Pipe Systems Pty Ltd 11 Christie Road Lonsdale SA 5160 Australia P: F: [email protected] AMITECH Poland Sp. z o.o. Biuro Handlowe: ul. Św. Michała Poznań Tel.: Fax: [email protected] AMIJACK-F1 V ENG