Box Jacking and Pipe Jacking

Box Jacking

 Box jacking is jacking a large precast reinforced concrete box horizontally through the
ground, usually beneath a road or railroad that must not be interrupted.
 The major advantage of the process is its essential simplicity.
 Only the exact prism of earth that will be filled by the jacked box is excavated.
 No intermediate ground supports are needed.
 The structure is built away from the roadway, in the clear, without the constraints of
shoring and traffic controls.
 When the structure is ready, a shield is fitted to the front, hydraulic jacks are installed
behind, and the box is pushed into final position while simultaneously the earth is
excavated from within.

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 Box Jacking

 The actual jacking generally takes only a few days to a week.

 During that time, traffic is proceeding overhead normally, unaware of the construction
below.
 The non-disruptive nature of the process together with its inherent safety, simplicity and
economy make box jacking a useful tool for the practicing civil engineer.

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 Box Jacking

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 Box Jacking

 Some examples of potential box jacking projects include storm drains, bike or pedestrian
trails, livestock or wildlife under-crossings, conveyors, pipe-ways and other
 industrial uses, small bridges, and roadways up to 4 lanes wide.
 Basically, applications of box jacking depend only on the creativity of the civil engineer
designing the project.

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 Box Jacking
 In principal, box jacking is very simple.
 The box is built on a greased “launch slab” lined up exactly with its final location.
 It is then pushed straight ahead, guided by curbs on the left and right to slide straight off
the launch slab.
 A steel shield installed on the front cuts the hole with minimal overcut.
 The force of the jacks is usually reacted against the earth at the back of the jacking pit
but this is not absolutely necessary.
 A box could theoretically be pulled into place.
 During jacking, lubricant is pumped around the box to ease its passage through the
ground.
 Upon reaching final location, grout is injected to displace the lubricant and
 permanently support the overlying ground.
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 Box Jacking

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 Box Jacking
 The box is best precast in one large block to the full length required.
 This is optimal, as rigidity and accuracy can be fairly guaranteed.
 Where space is limited the box can be cast in halves, thirds, or even more pieces.
 Although this reduces the total length of thrust column required, it introduces the
requirement of employing great care in constructing subsequent box sections to make
sure they are exactly aligned with the initial pieces.
 The box jacking process can be described in terms of its constituent subsystems, most
critical and primary of which is dimensioning.
 The box must closely fill the hole being cut by the shield at the front, and obviously, not
even slightly, overfill it.
 The mechanical subsystems are as follows:

07-08-2023 Prasad Gharat, Assistant Professor, SVKM’s NMIMS University, Mukesh Patel School of Technology Management and Engineering 8
 Box Jacking
 The mechanical subsystems are as follows:
 Jacking - backstop, thrust columns, hydraulic pumps, and jacks
 Excavation - shield, face control, digging equipment, transport.
 Ventilation - gas testing, fans and fan-line.
 Lubrication - mixers, pumps, distribution piping and manifolds.
 Guidance - lasers, levels, steering provisos.
 These systems, acting in concert, can propel the heaviest concrete structure straight into
the ground, producing a complete installation with maximum ease and economy.
 To realize these potential benefits it is very helpful if the project is originally designed with
box jacking in mind.

07-08-2023 Prasad Gharat, Assistant Professor, SVKM’s NMIMS University, Mukesh Patel School of Technology Management and Engineering 9
 Box Jacking
 The essential subsystems can be outlined as:
 Site preparation ― access, dewatering, etc.
 Jacking pit
 Shoring and reaction wall
 Launch slab
 RCBox and adaptation for jacking
 Dimensional modifications and extra rebar.
 Extra close external tolerances
 Shield on front
 Embeds for lubricating slurry distribution
 Pressure cells and instrumentation
 Grout holes
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 The essential subsystems can be outlined as:
 Jacking System
 Jacks
 Hydraulic pumps, plumbing, oil reservoir
 Thrust columns to backstop
 Material Handling
 Excavation System
 Face excavation
 Muck Transportation to Shaft
 Removal from Shaft

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 The essential subsystems can be outlined as:
 Ventilation System
 Guidance System
 Steering Provisos
 Lasers
 Communication Systems

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 Box Jacking

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 Box Jacking

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 Box Jacking

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 Box Jacking

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 Box Jacking

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 Box Jacking

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 Box Jacking

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 Box Jacking

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 Pipe Jacking
 Introduction
 Brief History
 Methodology
 Application
 Standards
 Equipment/Component
 Classification
 Alternative methods
 Pros & Cons

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 Pipe Jacking
 Introduction
 Pipe Jacking is the oldest method of trenchless technology.
 Pipes are pushed through the ground behind the shield using powerful jacks.
 Simultaneously excavation takes place within the shield.
 This process is continued until the pipeline is completed.
 The method provides a flexible, structural, watertight, finished pipeline as the tunnel
is excavated.
 Thrust wall is provided for the reaction of the jacks.

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 Pipe Jacking

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 Pipe Jacking

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 Pipe Jacking
 Brief History
 First mentioned in 1910, USA by Richardson & Mayo.
 In 60s, used in UK and APJA(American Pipe Jacking Association) is formed.
 In 70s, process is industrialized in Japan.
 In 80s, developed in Europe.
 1800 mm dia. trenchless pipe is laid for 460m in London,1982.
 560 m in water bearing sand and gravel, Byles, 1983.
 Komatsu introduced first fully automated machine in 1975 – IRONMOLE
 Today pipe jacking is remotely operated.

07-08-2023 Prasad Gharat, Assistant Professor, SVKM’s NMIMS University, Mukesh Patel School of Technology Management and Engineering 25
 Pipe Jacking
 Brief History
 First project is of 3.5km in 1998, Mumbai.
 In Cuttack 10km is constructed for sewer using trenchless method.
 Other projects of less than 8km is completed in Goa, Hyderabad, Kolkata, Delhi,
Assam etc.
 A total of around 100km is build so far using trenchless methods so far.
 Ongoing projects-
 55km of interceptor sewer along 3 major drains for reduction of pollution in
Yamuna river at New Delhi.

07-08-2023 Prasad Gharat, Assistant Professor, SVKM’s NMIMS University, Mukesh Patel School of Technology Management and Engineering 26
 Pipe Jacking
 Methodology
 Planning
 Procedure
 Specific feature
 Process based on soil
 Pipe jacking force
 Failure
 Solution

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 Pipe Jacking
 Methodology
 Planning
 Understand the site history and potential obstructions.
 Look at old aerial photos.
 Conduct a geotechnical program.
 Locate all existing utilities.
 Minimize costs.
 Develop the best cross section.
 Use the right materials.

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 Methodology
 Procedure
 The thrust pit and the reception pit are excavated at the required places.
 Then the thrust wall is set up in the thrust pit according to the requirement.
 In case of mechanized excavations, a very large pit is required.
 But in case of manual excavation, a small pit is enough.
 Thrust ring is provided to ensure the even distribution of stress along the
circumference of the pipe.

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 Methodology
 Procedure
 The number of jacks vary upon the frictional resistance of the soil, strength of
pipes etc.
 The size of the reception pit is to be big enough to receive the jacking shield.
 To maintain the accuracy of alignment a steerable shield is used during the pipe
jacking.
 In case of small and short distance excavations, ordinary survey method is
sufficient.
 But in case of long excavations, remote sensing and other techniques can be
used.

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 Pipe Jacking

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 Pipe Jacking

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 Pipe Jacking
 Methodology
 Specific feature
 Simple cyclic procedure.
 Utilizes thrust from hydraulic jacks to force the pipe forward
 Person have to enter in pipe for excavation.
 Excavation can be manual or by machine.
 Excavation takes place in front of an articulated shield.
 Designed for worker safety.
 Shield guided with individually controlled hydraulic jacks.
 Practically limited to dia. greater than or equal to 1075mm.
 Pipe installation process occurs from entrance and exit shaft.

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 Pipe Jacking

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 Methodology
 Process based on soil
 Unstable soil
 Face excavated simultaneously with the jacking operation.
 Minimize over excavation and the risk of face collapse.
 After pipe jacked into place hydraulic rams are retracted and another pipe
length is installed.
 Stable soil
 Face excavation may precede the jacking operation.
 All spoils removed through the inside of the pipe to the jacking pit.

07-08-2023 Prasad Gharat, Assistant Professor, SVKM’s NMIMS University, Mukesh Patel School of Technology Management and Engineering 35
 Pipe Jacking
 Methodology
 Pipe jacking force
 Force on jacked pipe includes:
 Pipe dead weight.
 Penetration resistance or face pressure.
 Soil-pipe friction.
 Other forces like:
 Curvature forces.
 Soil dead load.
 Railway or highway live load.
 Jacking force must not exceed allowable pipe compressive strength .

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 Pipe Jacking

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 Pipe Jacking

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 Pipe Jacking

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 Pipe Jacking

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 Pipe Jacking
 Methodology
 Failure
 Pipe generally fails from the corner first.
 Maximum force is acting at the edges due to:
 Uneven distribution of jacking force from one pipe to another.
 Unavoidable curvature.
 Elastic forces from pressure transfer rings at joints.

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 Pipe Jacking

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 Pipe Jacking

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 Pipe Jacking
 Methodology
 Solution

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 Pipe Jacking
 Standards
 BS 6164: 2011 – Code of practice for health and safety in tunneling in the
construction industry.
 BS EN 16191 – Tunneling machinery safety requirements

07-08-2023 Prasad Gharat, Assistant Professor, SVKM’s NMIMS University, Mukesh Patel School of Technology Management and Engineering 45
 Pipe Jacking
 Equipment / Component
 Jacking Pit.
 Jack.
 Pipe.
 Thrust Ring.
 Thrust wall.
 Lubricant.
 Intermediate Jack.
 Cutting-head.
 Pressure Transfer Ring etc.

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 Pipe Jacking
 Equipment / Component
 Jacking Pit.
 Jacking pit size is function of Length of pipe segments, Pipe diameter, Shield
dimensions, Thrust wall design, Jack size, Pressure rings and Guide rail
systems.
 Pit should be shored using Timber or steel piling.
 Placement of concrete slab on the floor is recommended.

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 Pipe Jacking
 Equipment / Component
 Jacking Pit.

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 Pipe Jacking
 Equipment / Component
 Jack
 Number and capacity of jack is a function of pipe size, length, skin friction,
intermediate jacks etc.
 It is suggested to provide even number of jacks.
 Pipe
 Pipe should be light weighted, smooth and strong enough to withstand all the
forces.

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 Pipe Jacking
 Equipment / Component
 Jack
 Pipe

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 Pipe Jacking
 Equipment / Component
 Thrust Ring.
 Thrust ring distributes force from jack head to pipe edges equally.
 A spacer is optional.
 Thrust wall.
 Thrust wall is provided behind the jack to transfer back thrust of jack to earth and
preventing jack to sink.

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 Pipe Jacking
 Equipment / Component
 Thrust Ring.
 Thrust wall.

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 Pipe Jacking
 Equipment / Component
 Lubricant.
 Lubrication is provided at outer edges of pipe using lubricant injection ports at
proper interval
 Intermediate Jack.
 Intermediate jack is provided in between the entry and exit shaft. Number of
intermediate jack depend on pipe length and jack capacity.
 Intermediate Jack must match pipe diameter

07-08-2023 Prasad Gharat, Assistant Professor, SVKM’s NMIMS University, Mukesh Patel School of Technology Management and Engineering 53
 Pipe Jacking
 Equipment / Component
 Lubricant.
 Intermediate Jack.

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 Pipe Jacking
 Equipment / Component
 Cutting-head
 Cutting-head or cutter is located at the front of pipe line. It cuts down the soil
ahead using mechanical motion into smaller fragments
 Pressure Transfer Ring etc
 Pressure transfer ring is used in between of two pipe at joints, it distribute the
pressure to succeeding pipe equally.
 It is made either of cork or synthetic material.

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 Pipe Jacking
 Equipment / Component
 Cutting-head
 Pressure Transfer Ring etc

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 Pipe Jacking
 Classification
 Based on pipe material
 Based on cutter head
 Based on excavation techniques

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 Pipe Jacking
 Classification
 Based on pipe material

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 Pipe Jacking
 Classification
 Based on cutter head

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 Pipe Jacking
 Classification
 Based on excavation techniques

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 Pipe Jacking
 Alternative Methods
 Non-steering Methods
 Moling / Piercing (Diameter 2-12 inches, Length 150 feet)
 Ramming (Diameter 8-72 inches, Length 300 feet)
 Auger Bore (Diameter 8-60 inches, Length 250 feet)
 Pilot Tube (Diameter 6-42 inches, Length 300 feet)
 Pipe Jacking (Diameter >42 inches, Length 1000 feet)
 Steering Methods
 Micro tunneling (Diameter 12-42 inches, Length 1500 feet)
 Horizontal Directional drilling (Diameter 2-48 inches, Length 6500 feet)
 Tunneling (Diameter >60 inches, Any Length)

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 Pipe Jacking
 Alternative Methods

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 Pipe Jacking
 Pros & Cons
 Advantages
 It avoids the excavation of trenches.
 Quick set-up, timely finish of projects.
 Good quality control and good grade of pipe used.
 Can be remotely operated.
 Versatile in various ground conditions.
 Cost efficient for large length pipe.
 Small surface settlements.
 Reduces disruption to existing services.
 Environment friendly.
 Less spoil.
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 Pipe Jacking
 Pros & Cons
 Disdvantages
 Costly for small lengths.
 Skilled personal is required.
 Dewatering of tunnel path is usually required.
 Not feasible for nature of soil changes drastically.
 Hard rock/Bed rock or very big boulders should not be present in the path line.

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 Conclusion
 Methods still evolving.
 Many hybrid methods emerging.
 Will never replace traditional open-cut methods; however, they complement each
other.
 To identify potential obstructions we can install a GPR(Ground Penetrating Radar) at
cutting head.

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 Pipe Jacking

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Thank You