Pipe Services

Esor Pipe Services a division of Esor Construction, has been party to every Southern African pipejacking record set to date and has contributed extensively to bringing the viability of the technique to the civil engineering fraternity in Southern Africa. Esor's work in this field, dating back to 1978, includes water supply, railway crossings, gas pipeline and bridge jacking projects across South Africa and neighbouring countries.

Pipejacking is a specialist technique used to install underground pipelines and culverts with minimal disruption to property, traffic or services on the surface. Pipes and culverts are progressively advanced through the ground using high performance hydraulic jacks.

Material at the head of the pipeline or culvert is excavated to the exact profile of the structure prior to jacking. This material is removed to the jacking pit via the structure being jacked where it is hoisted and tipped. Pipejacking is used for sewers and stormwaters, gas and water mains, electricity and telephone cables, box culverts and subways.

Esor also boasts a comprehensive suite of pipeline rehabilitation techniques ranging from Cured-in-place-pipe (CIPP) lining and Linings to Pipe Cracking.

Services & Products

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Esor operates in the highly specialised area of bridge jacking having successfully jacked 4 large bridge structures into place. In all instances these have been installed under live railway lines with minimal disruption to rail traffic, other than speed restrictions. A key advantage of bridge jacking is that it ensures minimal disruption to traffic making it a sought after method in a rapidly urbanising environment.

The group's pipejacking expertise can be applied to bridges where abutments and piers are split into smaller box units and jacked in one at a time.

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Esor is a leading provider of culvert jacking services which include jacking rectangular and arch sections as either precast sections or monolithic structures (cast-on-site).

Precast sections are available in a variety of sizes advantageously involve shorter lead times, require a smaller jacking set-up area and are manufactured under factory quality control conditions. Culvert can also be cast on site (sizes can be of any size, as per client’s specifications).

In similar ground conditions, culvert jacking allows for higher loads per square metre of surface area than traditional pipejacking.

1800 x 2500, 2500 x 3000, 2400 x 4200 Mould can be adjusted on request.

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Esor's pipejacking services deliver a high degree of accuracy in most ground conditions. Concrete pipejacking methods use a steel shield with hydraulic jacks that are positioned at the front of the pipeline. In unstable ground conditions the jacked structure may be installed as a sleeve through which the actual service will later pass or within which an in-situ invert may be constructed. A single sleeve pipe may be used to install a variety of smaller services.

Concrete pipes and culverts are readily available in a diameter ranging from 900mm to 3 000mm. Unit lengths may be varied to suit individual contract design and construction parameters. Working from both ends of the pipeline distances of 300m and more may be jacked by the use of intermediate jacking stations. In addition when high jacking pressures are anticipated, intermediate jacking stations can be installed at predetermined positions within the pipeline to reduce the overall load on the thrust wall and pipe joints. The number and positions of intermediate jacking stations depend on the length of pipeline and the prevailing ground conditions. On completion these intermediate jacks are removed and the pipes closed to form a butt-end joint within a steel sleeve.

The use of well pointing techniques in saturated conditions and the use of explosives when rock is encountered mean that pipejacking succeeds as a proven alternative under the most adverse and varying ground conditions.

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Guniting and Lateral Support methods are used. Esor sinks shafts up to a maximum diameter of 14m and to a 100m depth. The method is used of Mines and Ore passes. These shafts can either be inclined or horizontal.

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When a slab is casted incorrectly, jacks are used to jack the slab to its correct level.

Flagship Projects

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"The City of Cape Town approached Tuboseal in 2013 to investigate the possibility of rehabilitating the pipeline and utilising its much-needed capacity after many years of being degraded beyond use."

A CCTV inspection was the first and vital step in the rehabilitation process that ensued.  The city conducted several viability studies and finally appointed Aurecon Consulting Engineers to manage the trenchless rehabilitation project, comprising the CIPP lining of more than 3,300 metres of bulk sewer pipes ranging from 800mm to 1200mm in diametre, crossing underneath the N2 freeway and Baden Powell Drive.

Esor Tuboseal was awarded the project at a competitive rate and immediately began the careful logistical planning required in an environmentally sensitive and often inaccessible area.

The construction programme was expedited to ensure cleaning, final design, material manufacturing, shipping lead times and installation happened concurrently.  The dovetail effect of these activities placed the project firmly on track for completion well ahead of the programme and the (hopefully) rainy Cape Town winter.

The work itself was not without its challenges, but it did vindicate the depth of professionalism demonstrated by Esor Tuboseal and its commitment to preserving the natural environment.

"The rehabilitated pipeline runs alongside an ecologically sensitive wetland and the use of trenchless technology ensures that the ecological impact of the project is negligible.  Already 40% complete, we are on track to complete 3,300 metres of pipeline renewal without any significant excavations required."

Esor Tuboseal also adapted its hot water curing process to incorporate a high-performance water cooling system, which enables the recycling of process water and a saving of more than three million litres of drinking water amid critical water shortages in the Western Cape.

Apart from delivering a workd class product on this project, Esor Tuboseal set some audacious goals of 'safety first',  'first time right' and an unwavering resolve to maintain integrity with all stakeholders.

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This project was awarded to Esor Pipejacking division in March 2013.  The project required 21 jackings within a 6 month period.  The J10 pipeline, replacing the outdated J8 pipeline, will be 14km long starting at Simon Bekker Rd in Germiston and ending at Reservoir Rd in Boksburg.  Our scope also includes 1 stormwater canal crossing, 2 rail road crossings, 1 un-utilised railroad cutting, and 17 road crossings.  The project was completed in December 2014.

J10 Pipeline 1 J10 Pipeline 2 J10 Pipeline railway J10 Pipeline 3 J10 Pipeline 4

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The O6 project was awarded to Esor in May 2015 with a total of 9 jacks.

Since May 2015 we have finished three more jacks at Palmiet 06 line. These three jacks were handed over to the pipelines crew to push the steel pipe through the concrete sleeves. Our Original scope of work was to construct 9 pipe jacks on Portion B, but we were awarded an additional pipe jack on Portion A of the project. Progress to date on the remaining jacks is 7/91m at J8, 9/92m at J13 and 70/118m at J14. This means we still have adequate secured work on this line to keep us busy for the calendar year.

Typical of the area, we encountered a lot of mud and water at Jack 13 where we had to do piling to prevent mud slides and collapses. This however did not improve the conditions to prevent the mud slides and collapses. The soil was so saturated, that the 3m OD concrete pipe just dug into the soggy soil at the bottom and instead of jacking up, the pipe went down under its own weight.

We, as Esor, had to re-design the jack alignment and thinking on our feet it was decided to stop both jacks 13 and 14 than was planned to go under the N3 and Jack 14 under the secondary road.

The net effect resulted in an additional 20m VO approved, additional income and extended time in which to carry out the project.

In March 2016 we were awarded Jack 8 and right from the start we had difficulties with SANRAL and the Alberton Municipality. The jack was too close to the road and inside the SANRAL servitude and they wanted it moved. We then suggested 5 meters back and this was on a truck arrest road and the Municipality was not content on breaking up the arrest road in the event that it was needed during construction. We then requested for an open cut across the arrest road which was also denied. Eventually the jack went from a 53 meter jack to a 91 meter jack to satisfy every body’s needs.

This decision however brought additional problems that was not anticipated at the time. The pit and 15 meters of jacking is in backfilled ground conditions. With the heavy rains over the past few weeks we encountered numerous collapses in front of our pipe and every time we need to stop and make safe with nails and gunite before we can excavate further. The face of the jack is now under the arrest road and we have entered more solid rock and hopefully we will encounter no more collapses.

The Project's overall completion date is targeted for September 2016.

 

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We completed site establishment in early December 2015 at the R59 Highway and Johan Le Roux corners.  The client is Midvaal Municipality with consulting engineers Gibb and Esor as the main contractor.

The R59 consist of 5 jacks of which 4 jacks are for sewer lines and one jack is for the water main line.  The 5 jacks consist of the following lenghts;  the Highway is 211m long and will have three inter jack sections to maintain an even pressure on the jacks and to prevent the pipe from seizing up.  The end of the jack will also be the start of the Johan le Roux jack that will start about 3m higher than what the Highway jack will end on.  The Johan le Roux crossing at 106m long willl end inside an existing sewer mainhole to be connected on the old line.  The third jack is the water main line and is situated about 5km from the other two jacks at Aandblom Street and is also jacked underneath the R59 highway for a total distance of 98m.  All three these jacks are currently in progress.

The 4th jack will be underneath the railway line at Meyerton and will be 84m long.  The 5th jack will be from the same pit as the Highway jack and is jacked underneath a property for 52m.  This jack will also end inside an existing hole within the sewer line to be connected with the existing sewer system.  All 5 jacks are spected as 1200mm IS pipe, making it very strenuous on the legs of the workers going to the front of the face.  Ventilation will be a big priority and hydration of the workers will be continuous.  Only two workers can be at the face at a time as the working space is so small.  As the main contractor on this project we will also be inserting a HDPE 500/600 OD pipe through the sleeve pipe and will build manholes at the jacking pits.

After spending over 12 months inside a 1200mm diameter pipe, we managed to complete the over 80m jack and see dayling on the 8 March 2017.

With our tireless efforts in mind, the Client has agreed to award some additional works to Esor which include additional manholes and installation that is successfully underway.

The project is estimated to be complete by the end of April 2017.

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As we are targeting selected African countries, the award to Pipe Services of these 2 projects fits our strategy and reduce our risk and dependency on the South African market.

The Palapye Major Water Supply contract that include 6 pipe jack crossings below existing roads and railways.  The sleeves that will be used is 1800mm and 1500mm inside diameters with a total jack length of 217 meters.

The Mahalapye Major Water Supply contract include 4 pipe jack crossings below existing roads and railways.  1800mm and 1500mm diameter sleeves will also be used with a total jack length of 162 meters.

Treated Water will be running in the newly installed pipes from Water Treatment Plants.  The Palapye ring will be running from Botswana International University of Science and Technology water treatment plant whilst Mahalapye ring will run from Morale Hills water treatment works.

We have just completed the first crossing of 34m in Palapye, starting another crossing under a railway line to cover 20m and continuing with the 1st Mahalapye pipejack for the project running under neath A1 road covering 61m and expecting to complete by end March 2016.  The remaining pipejack crossings will all be completed by end of August 2016.

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Progress on the Wonderboom/Rooiwal bulk pipeline has advanced considerably with the recent completion of three important underground tunnels.

Pretoria motorists driving along Steve Biko Drive and Lavender Road over the past three months, would have been blissfully unaware that a team far beneath their wheels was digging one of the biggest underground precast culverts in South Africa.

According to project manager Anton Naude, each tunnel is 4,9 metres high and 2,7 metres wide, while the tunnel under Lavender Road is 40m in length supported by no fewer than 32 precast concrete structures, weighing 11 tonnes each.

"A hydraulic jack was used to push each structure into the tunnel which is wide enough to accommodate two small cars side by side.  A significant feature of the project was that the pipeline was laid without any disruption of traffic on the city's main arteries," he said.

The pipeline is a key component of Pretoria's 50-year development project and will supply water to Rainbow Junction and other industrial and residential growth areas to the north of the city.  The R130 million project began in 2013 and is scheduled for completion in 2015.

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