Box Pushing Technology: Seminar Report Submitted by Uvais.A REG NO:20010536 Civil Engineering

BOX PUSHING
TECHNOLOGY
SEMINAR REPORT
SUBMITTED BY
UVAIS.A
REG NO:20010536
CIVIL ENGINEERING
1
ACKNOWLEDGEMENT
2
CHAPTER CONTENT PAGE NO
ABSTRACT 4
1 INTRODUCTION 5-6
SALIENT
FEATURES AND
2 6-7
OBJECTIVE
OFSTUDY
BOX PUSHING
3 7-12
OPERATION
ANALYSIS OF
4 DESIGN OF 13-15
THRUST BED
CONCLUSION 16
REFERENCE 16-17
3
ABSTRACT
The project entitled analysis and design and execution of
cross traffic works in railways using box pushing
technique (RUB), illustrates about the work to be carried
out for the widening of existing roads using box pushing
techniques for rail under bridges. It also explains about
the methodology involved in execution of box pushing
technique. The design will be carned out as per Indian
standards, particularly Indian railways standards, IRC,
IRS, and IS CODES. In which the design of major
components thrust bed, precast box used for the widening
are done as per IRS codes. The design of pre cast box is
done using STAAD pro, it also includes the layout of
reinforcement details of two important structures used in
this method apart from conventional method 1.e., thrust
bed (main bed and auxiliary bed),pre cast box.
4
INTRODUCTION
In railways whenever there is a need to make a underpass

either for canal crossing, RUB’S(Rail under bridges),
programme of widening existing railway culverts etc.
BOX PUSHING TECHNIQUE is used. Since the work
has to be done without interruption to rail traffic, box
pushing technique is largely favored in comparison to
conventional methods. Transportation is one of the main
objects in the infrastructure of a developing country like
India. Most of the Indian intra national transportation 1s
done by railways. Railways were first introduced to India
in 1853 from Bombay to Thane. In 1951 the systems were
nationalized as one unit, the Indian Railways, becoming
one of the largest networks in the world. Comprising
115,000 km (71,000 miles) of track over a route of 65,000
km (40,000 miles) and 7,500 stations. Sixteen Zones in
2003. Each zonal railway is made up of a certain number
of divisions, each having a divisional headquarters.There
are a total of sixty-eight divisions. Bridges are a main link
in any transportation systems roadways as well as
railways. There are above | lakh bridges in India, most
them are over 100 or 150 years old. Some of the bridges
have outlived their service life. Generally bridges are
5
inspected by railway officials before and after monsoon.
If any bridge is in distressed condition either it will be
rehabilitated or rebuild depending on the conditions. If
any roadway and railway are crossing there will be a level
crossing(LC) whether manned or unmanned, Road Over
Bridge (ROB), Road Under Bridge (RUB) which can be
normal height or limited height Subway., depending on
the relative level.
SALIENT FEATURES
➢ One vent of 7.50 x 5.65m in side size and wall
thickness of 0.750m (outer size 9.00m x 7.15m.)
➢ Each Segment weighs 1100 metric tons and uses
60t of steel and 440 cum of concrete.
➢ The box is crossing 5 existing running lines and 5
future non running lines.
➢ Length of the vent is 69.36m long (43.00m length
pre cast by pushing technique and 26.36m length
by cast in situ)
➢ RCC Box with M-30 Grade concrete.
➢ Thrust bed of size 11.250x10.200m with M-25
grade concrete provided with 67 pin packets for
pushing.
➢ E Front cutting shield with 25mm thick M.S. plate
& 1.00m projection.
➢ E Rear shield with 12mm thick plate all round.
6
➢ E Drag sheets are provided in 3 layers with 0.60
mm thick each.
➢ Pushing of segments is done with hydraulic jacks of
183t capacity.
OBJECTIVE OF THE STUDY

In the present dissertation work on ANALYSIS &
DESIGN OF BOX PUSHING TECHNIQUE. Analytical
models of BOX PUSHING TECHNIQUE are prepared
and analyzed by using STAAD PRO software. In the
current study, work is carried-out on the methodology of
the box pushing technique, which provides widening of
existing RUB at chityal,nalgonda dist.
BOX PUSHING OPERATION

To push precast box segment, reaction is obtained from
thrust bed. For this, screed is dismantled at pin pocket
location, pin pockets are cleaned, pins are inserted and
Hydraulic Jacks8/10 nos. are installed between pins and
bottom slab of the box With packing plates and spacers.
7
➢ A 20mm thick plate is provided, butting against
bottom slab of box, in front of the Jacks to avoid
damage to concrete surface.
➢ Nail anchor plates are removed and earth is manually
excavated in front of cutting edge in a way to get
annular clear space of 300mm all-round.
➢ Anchor plates are refixed in position and uniform
pressure is applied to the jacks through Power Pack.
➢ After complete push (maximum 300mm) jacks are
released, protruding nails are gas cut/driven and jacks
again packed with packing plates and spacers.
➢ Process Is repeated till front box is pushed to required
position.
➢ Then 2nd box segment is slewed and brought in
position behind Ist box segment
➢ 8 nos. Jacks, each of 200 Tons capacity, are housed
between two box segments in addition to 8 nos. Jacks
already provided between thrust bed and 2nd box
segment.
➢ 3nos. Jacks, each of 100 Tons capacity, are provided
in 3 slots made in each side walls to facilitate
correction of line and level of box during pushing.
➢ Earthwork is now done in front of Ist box segment
and it is pushed. Protruding nails are gas cut/driven
and anchor plates are refixed in position.
8
➢ Thereafter, jacks housed between two box segments
are released and then 2nd box segment is pushed.
➢ Process is repeated till both the box segments are
pushed to required position.
➢ Cutting Edge is dismantled & front face of Ist box
segment is cast in plumb.
Fig:1 thrust bed
9
BOX CASTING AND PUSHING
➢ The RCC Box is cast in segments of convenient

lengths of Total pushing length.
➢ The Box section is designed as per IRS / IRC codes
Of practice for loading. Concrete grade normally kept
as M-30.
10
Fig:2 precast box
Fig:3 precast box segment
11
Fig:4 front shield
After the first box has reached the final position, the
second box will be pushed in such a way that a gap of
approximately 100mm remains between the units.
Cleaning the gap will be done and concrete edges will be
roughened, reinforcement will be placed in gap and
concreted, if required grouting will be done to make the
joint water tight. Suitable admixtures will be used in the
concrete used for filling the joint to make them water
tight.
12
Fig:5 hydraulic jack
ANALYSIS AND DESIGN OF THRUST BED
This report contains design of Thrust Bed for precast

RCC single box to be pushed inside the embankment for
“Proposed Widening of existing RUB, “Proposed
Widening of existing RUB, at Chityala village,near
Choutuppal in Nalgonda district”, on either side of
13
existing RUB with Box of size 7.5 x 5.5 mt at Railway
Km 205/200-300.
PRECAST BOX
➢ For the 7.5m span, we got the wall thickness as

750mm.
➢ For 6.4m clear height, we got the wall thickness as
750mm
THRUST BED
➢ We have provided thickness of thrust bed 750mm for

length of box 11m.
➢ The reinforcement details of precast box (tunnel),
thrust bed is shown in the Drawing sheet.
➢ Various unexpected situations are likely to occur
during the box pushing operations. Since the safety of
running trains is directly affected, proper planning
and implementation is essential for smooth
completion of work. Advance analysis of site, likely
problems that may arise and planning to tackle the
14
same will help the executive for speedy and safe
completion of the work.
ADVANTAGES
➢ In this technique there is no obstruction to the

railways and roadway traffic expect the speed
limit.
➢ Multiple rail lines are construct in box pushing
technique.
➢ Less time required for completion of project
work and the night working is also possible it
also help to reduce the
➢ Time period for the project.
➢ Heavy machineries are not used in cut and cover
method it may reduce the cost of pproject
DISADVANTAGES
➢ Skilled super vision and trained staff is required

➢ We can no change the alignment of box its
difficult to rectify initially
15
➢ There is a no scope for night working.
➢ In hard strata is very difficult to construct the
road under bridge.
➢ When the lateral and vertical alignment of box is
getting disturb then it is difficult to correct it.
FUTURE SCOPE OF WORK
➢ This was done for present need, for future expansions

box can be extended cast-insitu as there are no tracks,
thereby it can be done simpler & easier way, instead
of present box pushing technique.
➢ The present work done is on RCC box, prestressed
concrete can also be done, thereby the reinforcement
can be reduced greatly, and cost of PSC is more.
CONCLUSION
➢ With the box pushing technique, there is no

interruption to the traffic moving around.
16
➢ Better quality control due to the provision of
precast boxes.
➢ Quantities will be less as compared to the
conventional method of construction.
➢ The cost of construction is less as compared
with the conventional method.
REFERENCES
1.Alberto Zasso, Aly Mousaad Aly, Lorenzo Rosa and

Gisella Tomasini “wind induced dynamics of a prismatic
slender building with 1:3 rectangular section”
2.Proc of Bluff Bodies Aerodynamics & Applications
Milano, Italy, July, 20—24 200.
3.J. A. Amin and A. K. Ahuja “Experimental study of
wind pressures on irregular plan shape buildings”
4.Ryan Merrick! and Girma Bitsuamlak ‘‘Shape effects
on the wind-induced response of high-rise buildings”
Journal of Wind and Engineering, Vol. 6, No. 2, July
2009, pp. 1-18
17
5.M. Gloria Gomes, A. Moret Rodrigues and Pedro
Mendes “wind effects on and around Iand u-shaped
buildings” Department of Civil Engineering and
Architecture, , Technical University of Lisbon, Portugal
6.S. Swaddiwudhipong and M. S. Khan “Dynamic
response of wind-excited building using CFD” Proc of
Journal of Sound and Vibration (2002) 253(4), 7353754.
18

Box Pushing Technology: Seminar Report Submitted by Uvais.A REG NO:20010536 Civil Engineering

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BOX PUSHING

In railways whenever there is a need to make a underpass

OBJECTIVE OF THE STUDY

BOX PUSHING OPERATION

Fig:1 thrust bed

➢ The RCC Box is cast in segments of convenient

Fig:3 precast box segment

ANALYSIS AND DESIGN OF THRUST BED

This report contains design of Thrust Bed for precast

➢ For the 7.5m span, we got the wall thickness as

➢ We have provided thickness of thrust bed 750mm for

➢ In this technique there is no obstruction to the

➢ Skilled super vision and trained staff is required

FUTURE SCOPE OF WORK

➢ This was done for present need, for future expansions

➢ With the box pushing technique, there is no

1.Alberto Zasso, Aly Mousaad Aly, Lorenzo Rosa and

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