SHAFT CONSTRUCTION

We specialise in advanced microtunnelling shaft construction planning and select the most appropriate shaft design based on geotechnical conditions, groundwater considerations and available workspace all while holding safety to the utmost standard. With our global experience, our team draws upon best practices used in Europe and is one of the few companies in Australia providing precast segmentally lined caisson. Our experienced team offers an efficient approach to shaft construction in tunnelling projects and has successfully constructed shafts of various size and depth using jacked caisson, underpinning techniques, soldier piles, secant piles, shoring boxes and sheet piles.

What is shaft construction?

Many trenchless projects include shaft construction. Trenchless tunnelling, such as microtunnelling, and pipe jacking requires a pit or shaft excavated from the ground surface to launch and receive the tunnelling machine at the required tunnel depth. Shaft construction, or shaft sinking, is the construction of these launch and receival shafts. The launch shaft is an entry point for launching trenchless technology equipment such as a pipe jack and pre-fabricated pipe segments. The launch shaft may incorporate a thrust wall to spread reaction loads to the ground, and a concrete headwall with TBM launch seal to restrict inflows of groundwater and soil at the TBM penetration. The launch shaft must be large enough to accommodate the thrust wall, hydraulic jacking system, microtunnelling machine or pipe segment and headwall. The reception shaft is the exit point for the pipeline and is smaller in size as it only needs to accommodate the size of the microtunnelling machine. Most shallow shafts are rectangular to accommodate site constraints and provide cost effective shafts such as shoring boxes. Most deep shafts are circular as this shape is naturally structurally stable and requires fewer reinforcements.

Shaft construction techniques

There are multiple shaft construction techniques that can be used. As part of a feasibility study, our engineers will determine the best method based on the project’s needs, ground conditions and surrounding area. In some cases, our engineers work with local experts who understand the ground conditions and history in their community.

Jacked caisson

Jacked caisson shaft construction uses either pre-fabricated concrete segments or cast in situ concrete rings that are sunk into the ground using a hydraulic jacking machine. This method is specifically designed to keep water out of the construction zone and can be used in wet conditions, when groundwater is present or for underwater projects. It is also an effective shaft construction method when ground conditions are soft and sandy. Caissons are extremely tough and strong enough to withstand deep water pressure. This method is efficient, effective and creates immediate shafts.

Underpinning techniques

The underpinning technique is used when ground water is minimal. The shaft is constructed by excavating the ground and installing precast concrete segments and is often used in harder ground conditions.

Secant piles

Secant pile shaft construction is usually circular and uses a series of overlapping primary and secondary concrete piles. Typically, only the secondary piles are reinforced as they are constructed by drilling through the primary piles. Secant piles are an effective method to build a watertight shaft. They provide greater wall stiffness than other methods and can be used in difficult ground conditions.

Soldier piles

Soldier pile shaft construction uses vertical steel H piles and horizontal wood or concrete lagging to create the retaining wall. Soldier piles can be temporary or permanent depending on the project’s needs, but are primarily used for temporary construction. This method is efficient and cost effective, and can accommodate various shaft size and dimensions.

Sheet piles

Sheet pile shaft construction uses pre-fabricated steel sheet sections that interlock to create the shaft walls. They are typically driven into the ground using vibration. The shaft is excavated once all the sheet piles are driven into the ground, installing internal bracing to support the sheet piles depending on the shaft depth. For harder ground conditions and deep installations, predrilling may be required. Sheet pile shaft construction is widely used and the piles come in a variety of shapes and sizes. This method can be difficult in ground conditions with cobble stones and boulders.

Shoring boxes

Shoring Box shaft construction uses prefabricated steel panels and cross struts to support the ground. They are most suitable at depths of 6m or less in stable, reasonably self supporting, ground conditions. This method is an efficient and cost effective shaft solution.

Shaft construction advantages

  • Minimal impact on the surrounding area and ground surface

  • Limited dewatering

  • Supports microtunnelling in considerable depths

  • Can be easily sunk in urban, densely populated areas

  • Time and effort for remediation is relatively low

Planning a complex infrastructure project?

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