meyer-POLYCRETE® Jacking Pipes

meyer-POLYCRETE® Jacking Pipes
For trenchless construction of sewer pipelines
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Contents
2
1
Introduction ............................................................................................................................
3
2
Manufacture of polymer concrete pipes..............................................................................
3
3
Quality and characteristics of the meyer-POLYCRETE® jacking pipes .............................
4
4
Advantages of the meyer-POLYCRETE® jacking pipes application ...................................
5
5
Pipe manufacturing program ................................................................................................
7
6
Jacking pipe joints..................................................................................................................
11
7
Transport and storage ............................................................................................................
12
8
Technical support ...................................................................................................................
12
9
Reference list of unique jacking projects with use of meyer-POLYCRETE® pipes ...........
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1 Introduction
2 Manufacture of polymer
concrete pipes
For over 30 years, the meyer-POLYCRETE® company, with its seat
in Stendal (Germany), has been manufacturing pipes, manholes
and structures.
Polymer concrete is produced with aggregates and polyester resin,
features extremely good mechanical parameters and perfect
resistance to chemical corrosion.
Polymer concrete is an excellent material for sewage applications,
and in particular a new alternative for jacking pipes, meeting all
requirements of the trenchless installation.
The meyer-POLYCRETE® pipes are manufactured of polyester resin,
gravel, mineral sand and quartz fillers.
Pipe manufacturing is multi-stage process and includes the
following phases:
• Preparation of polymer concrete mass. The raw material mixing is an automatic, computer controlled process.
• Mould filling with the polymer concrete mass.
• Rotation and vibration of moulds in order to remove air from
the polymer concrete mass and maintain homogeneous structure.
• Mass binding inside the moulds (polymerization reaction)
•Mould separation.
• Pipe hardening in high temperature.
• Pipe Machining.
• Assembly of joints.
To date, hundreds of jacking projects have been completed, and
due to application of the meyer-POLYCRETE® pipes some of them
have become crucial projects in microtunneling, that set new
directions and possibilities of trenchless installations.
Meyer-POLYCRETE® pipes have been delivered to projects all
around the world, are highly appreciated by numerous engineers,
who describe them as safe and reliable material.
Meyer-POLYCRETE® technology is the most modern technology
of those presently used worldwide, setting new directions in
the scope of technology optimization, normalization and design
regulations.
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3 Quality and characteristics of the meyer-POLYCRETE® jacking pipes
The manufacturing of polymer concrete jacking pipes is performed under strict quality control in scope of testing raw materials
used in production as well as mechanical and geometrical
characteristics of a ready product.
The above method enables production of pipes with various
cross-section shapes (circular, egg-shaped, kite-shaped), with
unified structure at every spot of pipe cross-section and the same
mechanical features.
The polymer concrete pipes, due to applied raw materials and
patented manufacturing technology, are provided with unique
mechanical and useful characteristics, that guarantee very large
safety margin, both during their installation and within 50-year
exploitation period. Therefore, construction costs of new installation and its later maintenance can be significantly lower than
costs related to use of traditional materials.
Pipes are subject to long-lasting fatigue tests, results of which
there are long term parameters that confirm pipe life up to minimum 50 years of exploitation. The pipes and other products made
of polymer concrete are compliant with all quality requirements
specified in standards valid for this material all over the world.
Meyer-POLYCRETE® jacking pipes are meeting the following
standards:
• EN 14636-1
• DIN 54815-1 and 2
• ISO 18672-1
• ASTM D6783-05
Criterion
Symbol
Characteristic value
Unit
γ
23
kN/m³
Short term value
ES
23.300
N/mm²
Long term value
EL
8.200
N/mm²
Short term value
σrbs
≤DN500
>DN500
16
15
N/mm²
Long term value
σrbl
≤DN500
>DN500
9,4
8,8
N/mm²
Specific gravity 
Elasticity module
Tensile strength at ring bending
Compression strength
Fatigue strength (pulsating loads)
>90
6
N/mm²
N/mm²
Qty. of load cycles
2 x 10
-
Frequency
12
Hz
6
Shear strength
τs
>8,5
N/mm²
Internal surface roughness
k
≤0,1
mm
ν
0,25
-
-
to 2,4
bar
-
pH<1÷ pH>12
-
Poisson ratio
Leakproofness of joints
Standard joints. External
& internal water pressure.
Chemical resistance
High pressure rinsing resistance
-
>120
bar
Abrasion strength
after 100 000 cycles
am
≤0,5
mm
Maximum medium temperature
Standard polyester resin
-
min. 45
°C
Table 3-1 Characteristics of the meyer-POLYCRETE® jacking pipes
4
σc
2x σfat
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4 Advantages of the meyer-POLYCRETE® jacking pipes application
High compression strength
Joint water tightness
Very high values of acceptable jacking forces enable performance
of long tunnels reducing the number of intermediate jacking stations needed during a run and extending the distances between
reception shaft or jacking pits.
Advantages: Faster installation and reduced investment costs.
Standard joints guarantee water tightness up to 2,4 bar of external and internal water pressure; for special applications pressures
of up to 6 bar have been achieved.
Advantages: Possibility to build sewage pressure pipelines by use
of trenchless method.
System of joints with double gaskets
Joints of this type allow for leakage tests of each joint according
to the EN 1610 standard.
Advantages: Reduction of time and costs related to filling and
emptying a tested pipeline.
High tension and bending strength
Pipes during jacking may transfer significant tensions resulting
from boring head steering. The pipes preserve untouched wall
structure – no delamination of pipe wall structure.
Advantages: Possibility of curvilinear pipe installation.
High fatigue strength
It allows for pipe installation directly under transport routes
(roads, railway embankments, airports) without necessity of
applying additional shielding pipes.
Advantages: Safe installation.
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5
High chemical corrosion resistance
Smooth and non-absorbing pipe external surface
The materials used in the manufacturing of polymer concrete are
resistant to sewage environment inside pipelines throughout the
exploitation period.
Advantages: No necessity of service works related to pipeline
securing and maintenance during exploitation, no small scratches
occurring directly after installation.
Reduced pipe-soil friction coefficient, limited possibility of pipe
suction during uncontrolled, long technology breaks during
jacking.
Advantages: Faster and safe installation.
Abrasion resistance
The raw materials and uniform structure of polymer concrete
guarantee high resistance to abrasion. The abrasion effect does
not influence the pipe structural strength nor loss of load
capacity.
Advantages: Lower maintenance costs related to securing pipe
surface after long period of exploitation.
Smooth internal surface
High hydraulic efficiency and possibility of self-cleaning effect at
small channel lengthwise drops.
Advantages: Reduction of pipe cross section diameter by one
dimension in comparison to concrete pipes. Low expenditures
related to channel cleaning during exploitation period.
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Possibility of construction of side inflows from pipeline inside
Mechanical strength of pipes enables to perform side inflows
from pipeline inside by means of small jacking devices.
Advantages: Reduced costs of works connected with construction of starting chambers.
5 Pipe manufacturing program
The meyer-POLYCRETE® jacking pipes are manufactured with
three types of internal diameter cross section shape:
On the home and foreign markets the pipes are provided with
approvals of application in construction industry:
• Circular shape
• Kite shape
• Egg shape
DiBT Approval no. Z-42.1-250 / -353 (for pipes and manholes)
German Railway Authority Approval (EBA Certificate for pipe
installation under railway construction)
It allows for selection of suitable cross section, optimally adapted
to a given hydraulic characteristics of drainage basin. The pipes
are delivered in lengths according to the Table 5-1, 5-2, 5-3
and in special lengths per request.
Several other national / international certificates are existing.
Therefore, the pipes are used in municipal and transport construction industry and can be installed in areas with mining
damages.
OD
The DN250 ÷ DN2600 jacking pipes
(circular cross section)
s
DN
L
Internal diameter
DN
External diameter
OD
Wall thickness
s
Pipe length
L
Permitted
compression***
strength Vmax
Pipe weight
g
(mm)
(mm)
(m)
(kN)
(kg/m) *
250
360
55
1 and 2
530
120
300
400
50
1 and 2
505
125
400
550
75
1 and 2
1490
255
500
660
80
2
1900
335
600
760
80
2
2240
390
700
860
80
2
2400
445
800
960
80
2 and 3
2720
505
900
1100
100
2 and 3
4490
720
1000
1184
92
2 and 3
4140
735
1000
1280
140
3
7510
1155
1200
1482
141
3
5700
1370
1400
1720
160
3
7400
1810
1500 **
1820
160
3
7880
1925
1600
1940
170
3
8950
2185
1800
2160
180
3
10710
2580
2000
2400
200
3
13830
3185
2200 **
2630
215
3
16700
3755
2400 **
2870
235
3
20600
4380
2600
3100
250
3
24150
5150
* Maximum values / ** Diameter only available on request / *** Minimum values for straight drives in loose soil, without joint gaping
Table 5-1 Basic parameters of DN250 ÷ DN2600 jacking pipes with circular cross section
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The DN800 ÷ DN2000 jacking pipes (delta cross section)
OD
s
DN
L
Internal diameter
DN
External diameter
OD
Wall thickness
s
Pipe length
L
Permitted
compression***
strength Vmax
Pipe weight
g
(mm)
(mm)
(m)
(kN)
(kg/m) *
800
960
80
2 and 3
2720
555
1000
1184
92
2 and 3
4140
810
1230
1000
1280
140
3
7510
1200
1482
141
3
5700
1510
1400
1720
160
3
7400
2125
1500**
1820
160
3
7880
2300
1600
1940
170
3
8950
2595
1800
2160
180
3
10710
3025
2000**
2400
200
3
13830
3660
* Maximum values / ** Diameter only available on request / *** Minimum values for straight drives in loose soil, without joint gaping
Table 5-2 Basic parameters of DN800 ÷ DN2000 jacking pipes with delta cross section
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Jacking pipes to intermediate station
The offer of the meyer-POLYCRETE® jacking pipes includes also the
supply of intermediate stations consisting of leading and trailing
pipe as well as the steel case (but without hydraulic jacks).
The usage of an intermediate station provides significantly better
possibilities of long tunnel construction, enabling installation
continuity from one starting chamber.
Standard IJS design (S-IJS) for normal project conditions.
Extra IJS design (X-IJS) for special conditions, i.e. long jacking distance or high outer water level, including adaptable, additional
seal device
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Jacking pipes with lubricant injection nipples (Bentonite ports)
In order to reduce the coefficient of soil friction on outer pipe
surface during installation, the pipes with mounted injection
ports are applied. The ports are made of stainless steel and
adapted for connecting an installation for pipeline lubrication
with bentonite.
Injection nipple
120° 120°
120°
10
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Standard nipple diameter is 1”, however it is possible to order
other diameters. The position of nipples in the pipe (i.e. at 8, 12,
16 hours) and the requested amount per pipe will be installed
according to clients request.
6 Jacking pipe joints
Meyer-POLYCRETE® jacking pipes are connected with each other
by means of guide sleeve joints on the flarebare end basis.
The necessary condition for jacking pipes is the external diameter
of joint sleeve equal or smaller than external diameter of a
jacking pipe.
Seal
Steel sleeve
Seal
Wooden
distributing
ring
Polycrete® jacking pipe with steel sleeves DN 250 - DN 900
Besides a sleeve, the joint includes also elastomeric seals fitted
onto pipe bare end, aim of which is sealing the space between
sleeve and pipe bare end.
Epoxy glue Steel sleeve
Wooden distributing
ring
Seal
Stopper ring
Joint sleeves of various materials can be offered:
• stainless steel sleeve - V4A or V2A,
•sleeve of improved corrosion-resistant steel – WT,
•GRP sleeve*.
Polycrete® jacking pipe with steel sleeve DN 1000 - DN 2000
Several types of connections are available depending on pipe
diameter and used sleeve material.
Standard joints guarantee leaktightness up to 2,4 bar, but there
are available special solutions that will guarantee leaktightness
up to 6 bar (please contact the manufacturer or distributor).
Epoxy glue Steel sleeve
Wooden distributing Measuring Seal
ring
nipple
Seal
POLYCRETE® jacking pipe with steel sleeve DN > 2000
* only on request
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7 Transport and storage
8 Technical support
Meyer-POLYCRETE® pipes have been supplied for years to many
countries all over the world.
Our logistics specialists cooperate closely with the best transport
companies in order to develop the best forms of pipe transporting
directly to a construction site. Pipes are usually delivered individually or in packages by trucks. It is also possible to transport
pipes by water, air or railway. Finished pipes have pre-mounted
joints, seals, wooden rings for tension distribution on the face
plane and other details agreed with a customer at a quotation
stage.
Engineers of pipe manufacturer and supplier offer wide variety of
services related to:
Pipes have also factory fitted anchors for handling and transportation in factory and construction site.
Pipe storage should be done according to manufactures storage
manuals.
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• technical advice at design stage of an investment,
• static-strength and hydraulic calculations,
• development of drawings and diagrams of pipes and fittings,
• technical advice for contractors at a stage of pipe installation,
• solutions for special applications.
9 Reference list of unique jacking projects with use of
meyer-POLYCRETE® pipes
Diameter
Length
(m)
Year
Remarks
Germany
800 - 1200
407
1992
Pipe length 1m, curved drive with R=115m
Hamburg Graumannsweg
Germany
2600
437
2000
Curved drive with R=600m
Wuppertal - Animal Passage
Germany
2600
85
2001
Under motorway, depth up to 13m
Berlin - Arkonaplatz
Germany
600/900 eggshaped
153
N/A
Internal egg cross section
Lübeck - Herrentunnel - Seelandstr.
Germany
1000
2002
Reachstacker loading, depth up to 8m
Sydney - Hoxton Park
Australia
1400 - 1800
Attendorn - Sondern
Germany
1600
Hamburg - Eichenstr.
Germany
1600
New York - Warnerville
U.S.A.
Mazarron – Desaladora de
Valdelentisco
Project
Country
Leverkusen – Morsbroich
Castle
(mm)
1950
2003
2003
Rocky subsoil, depth up to 90m,
curved drive with R=600m
327
2006
Curved drive with R=300m
300
583
2007
Drive length up to 140m without IJS
Spain
2000
680
2007
Transportation of sea water, rocky subsoil
Montpellier
France
1200
324
2007
Depth up to 11m
La Coruna – Emisario Edar de Bens
Spain
1800
553
2008
Low pressure pipe , outlet to sea, rocky subsoil,
depth up to 18m
Warszawa – Kobiałka Street
Poland
800
5200
2008
Minsk
Belarus
1000
Aguilas - Desaladora - Gualadentin
Spain
2000
Hamburg - Wendenstr.
Germany
Zvolen - Sliac Airport
2008
Depth up to 17m
410
2009
Low pressure pipe - outlet to sea
1200 kiteshaped
455
2009
Curved drive with R=500m
Slovakia
400-1200
291
2009
Aircraft Loading
Powidz – Military Airport
Poland
400 - 1200
1180
2011
Aircraft Loading
Freiberg - ZKA Collecting Sewer
Germany
1400
1368
2010
Drive length 300m without IJS, curved drive
with R=345m, 12m depth
Włocławek – DK1 – 1st stage
Poland
200 - 1200
1819
2010
Very intensive traffic
Gdańsk – Airport
Poland
1400 kiteshaped
420
2010
Aircraft Loading
Warszawa – Połczyńska
Street
Poland
600 - 1400
1050
2010
Gdańsk - Arena Baltycka Wielopole
Poland
1600 kiteshaped
1536
2011
Railway Loading
Toruń – Bridge
Poland
300 - 2000
1384
2011
Depth up to 10 m
Katowice - GIGABLOK
Poland
500 - 1800
2683
2011
Lowest cover of 1m, transport loading
Logan
Australia
250 + 500
1178
2011
Rocky subsoil
Berlin Blankenburg - Triftstr.
Germany
600
11
2011
Depth up to 10m
Honolulu - BWFM 1
U.S.A. Hawaii
1800
390
2012
Low pressure pipe, curved drive
with R=274m
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15
Every effort was made to ensure the contents
of this brochure was consistent with the
facts.
However, the meyer-POLYCRETE® company
and its subsidiaries do not take liability for
any problems, that may arise because of
errors in this publication.
Therefore, customers should direct inquiries
to a potential product supplier in order to
check usefulness of any products supplied
or manufactured by the meyer-POLYCRETE®
company and/or its subsidiaries, before using
these products.
meyer-POLYCRETE GmbH
Hoher Weg 7
D-39576 Stendal
Tel. +49 (0) 39 31 / 67 29 - 0
Fax +49 (0) 39 31 / 67 29 - 30
[email protected]
Nr. 355.1 09/12 200 Schm
Distributor: