POLYCRETE Jacking Pipes Brochure

Underground pipe jacking requires high qualitypipes and successful safe instal lat ions: Meyer POLYCRETE® jacking pipes are corrosionresistant and provide the very high axial compressive strength required for jacking. POLYCRETE® jacking pipes are made of aggregate and polyester resin with properties and dimensions specified in German StandardDIN 54815. P O L Y C R E T E ® J A C K I N G P I P E SQUALITY AND SAFETY ABOVE ALL.2S u c c e s s f u l P i p e I n s t a l l a t i o n sd e p e n d o n Q u a l i t y P i p eMicrotunnelling technology has developed rapidly inrecent years and reached a high standard worldwidebecause it is environmentally friendly and cost-effective.Microtunnelling projects to be successful requirehigh-quality, high strengthjacking pipes which are easyto install.P o l y m e r C o n c r e t e – the ideal Sewer MaterialPOLYCRETE® jacking pipesby Meyer are made up of aggregate, filler and polyester resin. Cementand water are not used.Polyester as bonding agentprovides excellent resi-stance to corrosion. Thematerial properties and dimensions are specified i n G e r m a n S t a n d a r d DIN 54815. The material is commonly called polymer concrete (PRC).This composite material con-forms with DIN 16946, part 2, type 1140. Thehomogeneous bond of resin and aggregate materialscombine to provide very high axial compressive strengthsand bending strengths with a thinner wall thickness andless weight than other jacking pipes. Othe r Advan tage s o f t h e Ma t e r i a l i n c l ude :• Polyester is extraordinary resistance to most acidand caustic solutions• The quartz aggregate resists chemical attack• The material structure is capillary-free and does notallow water absorption or gas diffusion.These features make MeyerPOLYCRETE® jacking pipesresistant to sewage, gases,corrosive solutions, andaggressive soil (pH range 1.0to 10).T h e P O L Y C R E T E ®J a c k i n g P i p ePipes are manufactured in 1, 2 or 3 meter lengths depending on pipe diameterand jack ing equ ipmen t requirements. Connections tomanholes are manufactured inshorter lengths in accordancewith the requirements of the client. Production in metal molds ensures accurate size andsmoothness of the interior andexterior pipe surfaces. Theinner pipe diameter is identicalwith the nominal diameter (DN). The outer pipe diameteris compatible with most standard microtunnelling andjacking equipment and can be adapted to meet specificstructural requirements and machine sizes.MICROTUNNELLING, THE TECHNOLOGY FOR THE FUTURE.4QUICK CONNECTIONS.M a n h o l e C o n n e c t i o n sFor diameters up to DN 800 and lengths of 1 to 2 meterspipe jacking from round shafts is usually preferred.Rectangular shafts are predominantly used for larger pipediameters or longer lengths of pipe. Installing manholes atthe insertion and reception shafts is very costly, especiallyfor large diameter pipe. It is more economical to installPOLYCRETE® prefabricated manholes featuring the sameproperties as the POLYCRETE® jacking pipes.POLYCRETE® prefabricated manholes are installed in theinsertion and reception shafts. The manholes have standard-size connection sleeves. The remaining spacebetween the jacking pipes and a manhole is usually bridged by a closure pipe and a push-on tightening sleeve.H o u s e C o n n e c t i o n sHouse connections are made directly to the sewer. Bellsand spigot ends of standardized pipe materials are typically used. The necessary tapping can be made usingcommercial core drilling equipment. Pipe jacking of house connections (sewer laterals) makeseconomic sense if the house connections can be madefrom the same shaft used for the jacking of the sewer.M e y e r o f f e r s t h e c o m p l e t e S y s t e m :• Reinforced concrete insertion and reception shaftsDN 2000 - DN 3200• POLYCRETE® jacking pipes DN 200 - DN 900 for microtunnelling• POLYCRETE® jacking pipes DN 1000 - DN 2600 • POLYCRETE® jacking pipes DN 800 - DN 1800with kite shaped cross-section• POLYCRETE® manholes DN 1000 - DN 2600• POLYCRETE® jacking pipes DN 150for house connections (sewer laterals)The complete system is available from a singlesource offering easy and quick coordination ofsupplies. From Meyer.5RELIABLE AND SAFE.POLYCRETE® jacking pipes meet the requirements ofStandard A 125 of ATV (German Association for WaterPollution Control). This standard requires parallel pipe endsperpendicular to the pipe axis. This is guaranteed by milling each individual pipe. Parallel pipe ends perpendicalurto the pipe axis ensure an even distribution of jacking forces over the entire pipe wall. The exterior pipe surface isvery smooth which lowers friction during pipe jacking.Pipe quality is monitored in accordance with the QualityControl and Testing Regulations of Deutsche Bahn AG(German Rail) by MPA NRW (Material Testing Institute ofNorth Rhine-Westphalia, Germany). All POLYCRETE®jacking pipes used in Germany and exported worldwideare required to obtain this approval.Upon receipt of an order Meyer prepares the static calculations based on ATV-Standard A 161. The installationrequirements should be indicated in as much detail as possible. Please ask for Meyer’s form „LOAD DATA for POLYCRETE® Jacking Pipes conforming to DIN 54815“.J a c k i n g P i p e J o i n t sA sealing element and a guide sleeve make up the jackingpipe joint. For diameters up to DN 1143 the sealing element is fixed to the pipe and the guide sleeve is a floating element. For larger diameters the sealing elementand the guide sleeve is fixed to the pipe. Only materialsspecified by ATV-Standard A 125 are used for seals andguide sleeves. The quality of the pressure distribution ring isessential for the even distribution of axial forces on the pipe.Chipboard or knot-free soft wood rings are used to distribute the jacking forces on the end of the pipe. Thepressure distribution rings are supplied with the pipe andcan be installed on request.6H o u s e C o n n e c t i o n s D N 1 5 0 Trenchless house connections installed by microtunnellingmachines are gaining in importance. Jacking of sewersand house connections from the same drive shaft providestechnical and economical advantages. POLYCRETE®house connection pipes can take the required high compressive loads. They are used for cost-effectiveness,high strength and ease of installation.P O L Y C R E T E ® J a c k i n g P i p e s D N 2 0 0 –D N 9 0 0 f o r M i c r o t u n n e l l i n gWith POLYCRETE® jacking pipes it is possible to microtunnel two manhole reaches at one time – with subsequent installation of a manhole midway between thetwo manholes. The superior capacity of POLYCRETE®jacking pipes to carry high compressive loads allows thistime and cost saving procedure. A steel sleeve providesthe optimum in safety for a flawless pipe connection, evenwith unfavorable ground conditions. POLYCRETE® Jacking Pipes DN 1000 – DN 2600The high jacking load capacity of POLYCRETE® jackingpipes makes very long drives possible. To achieve still longer drives intermediate jacking stations are used. ForPOLYCRETE® jacking pipes we supply intermediatejacking stations, including the specially designed leadingand trailing POLYCRETE® interjack pipes, the steel guidecollar, and the steel and wooden pressure distributionrings. Intermediate jacking stations can also be made tocustomer specifications. The microtunnelling/jackingequipment supplier will provide the hydraulic jacks. Bentonite is usually injected through injection nipples in thepipe wall to reduce surface friction. The injection nipplesare installed in the POLYCRETE® jacking pipe at our plant.The nipples can be our design, made to customer specification or be supplied by the customer to us for installation. In case curved drives are necessary we willmake the required alterations to the pipes, sleeves, andpressure distributing rings in order to achieve a maximumof safety during jacking.POLYCRETE ® Ja ck i ng P i pe s DN 800 – DN 1800 w i th k i t e - shaped Cross -Sec t i onJacking pipe with kite-shaped cross-section was developedin Hamburg to meet the specific hydraulic requirements ofthat City. Compared to pipe with a circular cross-sectionthis new jacking pipe ensures a higher flow speed at lowwater levels, increasing the self-cleaning effect. When oldHamburg egg-shaped brick sewers are replaced by POLY-CRETE® jacking pipes with a kite-shaped cross-section asignificant gain in valuable storage volume is achieved.THE FULL RANGE.7TO THE POINT.POLYCRETE® Jacking Pipes stand out for:• high compressive strength = high jacking force and maximum safety• steel guide collar = maximum safety during jacking• smooth, even, non-absorbing outer pipe surface = reduced friction• parallel pipe ends = uniform distribution of jacking forces• high dimensional accuracy = no ovality, tight joints, and perfectly matching pipes• elasticity = reduced point loading and risk of rupture• low weight = ease of installation• adaptable dimensions = suitable for all microtunnelling and jacking equipment• complete system = reinforced concrete insertion and reception shafts, POLYCRETE®jacking pipes, and POLYCRETE® system manholes all from the same supplier• smooth, even inner surface = high flow rate• high corrosion resistance = reliability throughout a long service life• tested fatigue strength under cyclic load = installations under German, Canadian and U.S. railroad tracksYOUR PROJECT CAN BENEF I T FROMTHESE ADVANTAGES. JUST CONTACT US.THE EARL IER, THE BETTER.M E Y E R R O H R + S C H A C H T G M B HOtto-Brenner-Str. 5 • D-21337 LUENEBURGTel.+49 4131/953-0 • Fax +49 4131/953-255e M a i l : i n f o @ m e y e r - p o l y c r e t e . c o mw w w . m e y e r - p o l y c r e t e . c o m