SCHOOL OF CIVIL ENGINEERING INDIANA DEPARTMENT OF HIGHWAYS JOINT HIGHWAY RESEARCH PROJECT Final Report JHRP-89/8 CONSTRUCTION SPECIFICATIONS FOR HIGHWAY PROJECTS REQUIRING HORIZONTAL EARTH BORING AND/OR PIPE JACKING TECHNIQUES Donn E. Hancher Thomas D. White D. Thomas Iseley c>- UNIVERSITY JOINT HIGHWAY RESEARCH PROJECT Final Report JHRP-89/8 CONSTRUCTION SPECIFICATIONS FOR HIGHWAY PROJECTS REQUIRING HORIZONTAL EARTH BORING AND/OR PIPE JACKING TECHNIQUES Donn E. Hancher Thomas D. White D. Thomas Iseley Purdue University Division of Construction Engineering and Management Final Report CONSTRUCTION SPECIFICATIONS FOR HIGHWAY PROJECTS REQUIRING HORIZONTAL EARTH BORING and/or PIPE JACKING TECHNIQUES TO: H. L. Michael, Director July 7, 1989 Joint Highway Research Project FROM: T. D. White, Research Engineer Project: C-36-672 Joint Highway Research Project File: 9-11-26 Attached is the Final Report for the above referenced project. The study was conducted and the report authored by Dr. D.T. Iseley, Graduate Research Assistant, under the direction of Professors T.D. White and D.E. Hancher. The major objective of this study was to evaluate the various horizontal earth boring and pipe jacking techniques used by highway agencies for placing drainage structures and utilities under high- ways and railroads. Background information on all known methods, materials, and equipment are provided in the report. Current design procedures are reviewed and summarized. Recommended modifi- cations to existing guidelines and specifications are presented. This Final Report is forwarded for review and acceptance by all sponsors as fulfilling the objectives of the study. Sincerely, Thomas D. White Research Engineer Civil Engineering Building. Room 1223 • West Lafayette. IN 47907 • 13171 494-2240 Digitized by the Internet Archive in 2011 with funding from LYRASIS members and Sloan Foundation; Indiana Department of Transportation http://www.archive.org/details/constructionspecOOhanc CONSTRUCTION SPECIFICATIONS FOR HIGHWAY PROJECTS REQUIRING HORIZONTAL EARTH BORING and/or PIPE JACKING TECHNIQUES Joint Highway Research Project Project No. : C-36-672 File No. : 9-11-26 Conducted For : Indiana Department of Highways Prepared By : D. E. Hancher, Research Engineer T. D. White, Research Engineer D. T. Iseley, Research Assistant This research was carried out by the Joint Highway Research Project, Purdue University, under the direction of the first author as the principal investigator. The contents do not necessarily reflect the official views or policies of the Indiana Department of Highways. PURDUE UNIVERSITY School of Civil Engineering West Lafayette, Indiana July, 1989 Ill ACKNOWLEDGMENTS The authors wish to express their sincere appre- ciation to the Indiana Department of Highways (IDOH) for making this research project financially possible through the Joint Highway Research Program (JHRP) which has been in existence for more than 50 years at Purdue University. Special acknowledgements are extended to Mr. Max K. Hunter and Mr. Don G. Scott, Construction Division of IDOH, for serving as an advisory committee and assisting in the coordination of IDOH seminars. The authors wish to acknowledge numerous individ- uals and organizations for their valuable support and contributions which provided the material that made this report possible. Special appreciation is extended to: * The many members, from across the United States, of the Horizontal Boring, Jacking & Tunneling Task Force which was established by the Horizontal Earth Boring and Pipe Jacking Committee of the National Utility Contractors Association (NUCA) to provide construction industry input. IV * The forty state highway departments, from across the United States, that responded to the request for guidelines, specifications, examp- les, case studies, reports, etc. concerning trenchless excavation. * Mr. James Thomson, Jason Consultants, S.A. * Prof. T. D. O'Rourke, Cornell University * Mr. R. A. Koenig, Jr., Byrd, Tallamy, MacDonald and Lewis, Consulting Engineers. * Mr. M. E. Argent, Pittsburg Pipe * Mr. D. R. Church, NUCA Task Force * Mr. L. L. Liotti, Midwest Mole, Inc. * Mr. D. Melsheimer, Melfred Borzall,Inc. * Mr. W. Boeckman, Charles Machine Works, Inc. * Mr. L. J. Barbera, American Augers, Inc. * Mr. L. Di Pentino, Pipe Jacking Consultant * Mr. A. A. Daniel, BorTunCo of America, Inc. * Mr. D. E. Myers, I.D.O.H. - Permits * Mr. B. Van Meter, McLaughlin Boring Systems * Mr. W. L. Thaxton, Thaxton Const. Co. * Mr. D. A. Douglas, N.I.P.S.C.O. * Mr. M. Akkerman, Akkerman Manufacturing * Dr. A. H. Miki, Iseki Poly-Tech, Inc. * Mr. M. Garver, BRH-Garver, Inc. * Mr. R. H. Brinton, Flowmole Corporation HIGHLIGHT SUMMARY On the basis of a preliminary evaluation, it was determined that a high degree of variation in specifica- tions for horizontal earth boring, pipe jacking, and utility tunneling projects exists across the United States. It was also recognized that many designers and highway department representatives were not familiar with current methods, materials, and equipment being utilized. Since the contract documents, detailed plans, and specifications are the primary instruments of commu- nication for the contractor, then it is understandable why "incomplete, inaccurate, and faulty construction specifications often result in a large number of field problems " [55]. Designers and highway depart- ments have a professional responsibility to insure that their specifications are accurate and complete. This report is a result of in-depth research into the development of specifications for the rapidly evolving area of trenchless excavation construction (TEC). A summary description of the various methods, equipment, and materials commonly utilized in the United States is provided. The design principles and practices for various conditions and materials are presented. Recommended guidelines and specifications have been developed and are presented in this report. VI TABLE OF CONTENTS Page LIST OF TABLES ix LIST OF FIGURES xii CHAPTER 1 - INTRODUCTION, 1.1 General Description Of The Industry And Problem , 1.2 Justification For Research On Trenchless Placement Of Utilities 12 1.3 Description Of The Research Methodology , 16 1.4 Description Of Research Limitations 18 CHAPTER 2 - EVALUATION OF TRENCHLESS EXCAVATION METHODS , 19 2.1 Horizontal Earth Boring 19 2.1.1 Auger Horizontal Earth Boring. 21 2.1.1.1 Method Description 21 2.1.1.2 Main Characteristics 50 2.1.1.3 Major Advantages 54 2.1.1.4 Major Disadvantages 54 2.1.2 Compaction Method 55 2.1.2.1 Method Description 55 2.1.2.2 Main Characteristics 63 2.1.2.3 Major Advantages 65 2.1.2.4 Major Disadvantages 66 2.1.3 Slurry Horizontal Rotary Drilling Method (SRD) 67 2.1.3.1 Method Description 67 2.1.3.2 Main Characteristics 78 2.1.3.3 Major Advantages 82 2.1.3.4 Major Disadvantages 83 13 Vll Page 2.1.4 Water Jetting Method 84 2.1.4.1 Method Description , 84 2.1.4.2 Main Characteristics 85 2.1.4.3 Major Advantages , 86 2.1.4.4 Major Disadvantages , 86 2.1.5 Pipe Ramming Method , 87 2.1.5.1 Method Description , 87 2.1.5.2 Main Characteristics , 90 2.1.5.3 Ma jor Advantages , 92 2.1.5.4 Major Disadvantages 92 2.1.6 Directional Drilling Method..., 93 2.1.6.1 Method Description , 93 2.1.6.2 Main Characteristics , 98 2.1.6.3 Major Advantages , 100 2.1.6.4 Major Disadvantages , 100 2.1.7 Flowmole Guidedril Method , 101 2.1.7.1 Method Description , 101 2.1.7.2 Main Characteristics , 105 2.1.7.3 Ma jor Advantages , 106 2.1.7.4 Major Disadvantages , 106 2.1.8 Micro - Tunneling Method , 107 2.1.8.1 Method Description 107 2.1.8.2 Main Characteristics , 116 2.1.8.3 Major Advantages , 117 2.1.8.4 Major Disadvantages , 117 2.2 Pipe Jacking 118 2.2.1 Method Description , 118 2.2.2 Main Characteristics 126 2.2.3 Major Advantages , 128 2.2.4 Major Disadvantages 128 2.3 Utility Tunneling 129 2.3.1 Method Description 129 2.3.2 Main Characteristics , 134 2.3.3 Major Advantages 135 2.3.4 Major Disadvantages , 136 CHAPTER 3 - EVALUATION OF MATERIALS UTILIZED FOR TRENCHLESS EXCAVATION , 137 3 . Steel Casing Pipe , 137 3.2 Reinforced Concrete Pipe (RCP)...., 149 3 . Corrugated Metal Pipe 164 3.4 Polyvinyl Chloride Casing Pipe (PVC). 168 3.5 Steel Tunnel Liner Plates 170 3.6 Hobas Fiberglass Pipe 176 Vlll Page CHAPTER 4 - DESIGN METHODOLOGY 178 Geotechnical Considerations 182 Casing Pipe 187 Carrier Pipe 213 Protection Practices 214 Bore Pits 216 Process Simulation For Trenchless Excavation 219 CHAPTER 5 - SPECIFICATION RECOMMENDATION 230 5.1 Section 716 - Trenchless Excavation Construction (TEC) Methods 230 2 716.02 Materials 235 3 716.03 General Requirements 235 4 716.04 Ground Water Control 242 5 716.05 Access Pits / Shafts 245 6 716.06 Horizontal Earth Boring 248 7 716.07 Pipe Jacking 255 8 716.08 Utility Tunneling 256 9 716.09 Ventilation 257 10 716.10 Lighting 258 11 716.11 Grouting 258 12 716.12 Casing/Carrier Void Filler 259 13 716.13 Bulkheads 259 14 716.14 Obstructions/Changed Conditions 259 15 716.15 Abandonment 260 16 716.16 Measurement 260 17 716.17 Payment 260 18 Materials 261 19 Accuracy 270 CHAPTER 6 - CONCLUSIONS AND RECOMMENDATIONS... 271 6.1 Summary Of Investigations. 271 6 . 2 Conclusions , 275 6.3 Recommendations , 277 6.4 Future Research , 278 REFERENCES , 279 IX LIST OF TABLES Table Page 2-1 Physical Characteristics of Horizontal Boring Augers 22 2-2 Boring Pit Dimensions for Track-Type of Auger Horizontal Earth Boring 26 2-3 Ground Conditions Chart for Track- Type Auger Horizontal Earth Boring Procedures 32 3-1 Steel Pipe Sizes With Weights Per LF for Various Wall Thicknesses 145 3-2 Available Steel Pipe Sizes and Recommended Wall Thicknesses 145 3-3 Typical Thrust Force Per Linear Foot Required To Jack Reinforced Concrete Pipe 154 3-4 Minimum and Maximum Height of Cover for Railroad Cooper E 80 and Highway H 20 Liveloads plus Impact for Cohesive and Noncohesive Soils for Various Gages of Tunnel Liner Plates 172 4-1 Coefficient of Cohesion "c" for Various Soil Materials.