Construction of Road Under Bridge by Precast

RCC Box 2 x 5.00x 5.00 m by Box Pushing

Technique in Hubli-Bangalore Section
Dr. R. S. Dubey *
Prem Narayan **

Synopsis : Due to growing traffic on road as well as on rail, necessity of

crossing the rail and road is on the steep rise. To construct such opening,
with minimum disruption to train services and road traffic, is a challenge to
the Railway Engineers. Box pushing technique is one of the suitable methods
for such situations. This paper deals a real case of Box Pushing carried out
under train running traffic condition by providing Road under bridge for Level
Crossing No. 261 between Hubli - Bangalore line. This paper mainly deals
execution part of the Box pushing and precautionary measures for successful
completion of work.

1.0 Introduction
Government of Karnataka (GOK) has proposed two lane sub way
due to up gradation of Karwar- Ilkal State Highway 6. As the TVU is
less than 1 lakh, hence the cost is fully borne by GOK. The scope of
work was construction of subway including approaches. This subway
was of 2x5. 0x5.0 m road under bridge (RUB) to be provided for
elimination of level crossing no. 261 at km 423/1-2 between Gudgeri
and Yelvigi stations in Hubli-Davangere section. This bridge involved
2200 Cum of Reinforced concrete of M30 grade with 330 tons of
steel reinforcement. The construction was done by box pushing
technique involving 180 tonne capacity hydraulic jacks. The RCC
box was cast in segments of 8.5 to 11.00m length. A drag sheet was
used to avoid the friction between the formation earth and the box
during pushing operation.
This work of RUB will also eliminate the Manned Level Crossing No.
261 which will ensure safety of running trains as well as saving of
man power as 3 men are deputed for the gate.
* Chief Engineer (Construction), South Western Railway, Hubli
** Dy. Chief Engineer (Construction), South Western Railway, Hubli

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2.0 Site Plan

The state high way is crossing the Hubli-Banglore Railway line at
KM 423/1-2 at a skew angle of 65 degrees and track is on 2.8 degrees
curve. Either side of track is on bank, hence subway was found
feasible instead of ROB. Considering 5.00 m vertical clearance for
road traffic, top of bottom slab of RCC box is decided duly taking
consideration of depth of track and 0.75 meter earth cushion (1.00
earth cushion is preferred for box pushing). Alignment of road is
made straight duly eliminating road curves. To cater for traffic, two
RCC boxes of size 5.00 x 5.00 meter are pushed independently
keeping 1.00 meter gap between boxes.

Fig. 1 : Location Map

3.0 Salient Features

1)
2)
3)
4)
5)
6)
7)
8)
9)

Box size
- 2x 5.00x5.00 meters
Number of RCC segments - 4 numbers on Hubli end and 5
numbers on Bangalore end.
Box length - 43.00 m Hubli end and 53.50 m Bangalore end.
Top and bottom slab thickness
- 500 mm
Side walls thickness
- 500 mm
Quantity of RCC in boxes
- 1100 cum
Quantity of RCC in road works
- 800 cum.
Quantity of RCC in retaining walls - 300 cum.
Quantity of total steel involved
- 330 Tonnes.
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10) Hubli end box pushing was commenced on 26.08.11 and

concluded on 29.09.11 (33 days). A total length of 43 meter
was pushed achieving an average progress of 1.3 meter per
day.
11) Bangalore end box pushing was commenced on 02.10.11 and
concluded on 02.11.11 (30 days). A total length of 53.50 meter
is pushed achieving an average progress of 1.78 meter per day.
Removing the earth from inside the box was done manually
where the strata was loose. Hard strata were removed by
engaging Poclain -200.
12) Total 18 hydraulic jacks of 180 tonne capacity each and 3 power
packs were used during pushing operation of the box segments.
Minimum force of 120 tonne and maximum force of 600 tones
was applied during pushing of segments. Minimum 2 and
maximum 6 jacks were engaged for segments.

Fig. 2

Fig. 3 Typical box reinforcement details

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13) Drag sheets 1.00 mm thick 0.90 m wide, 3 numbers in 4 rows in

each box were used.
4.0 Details of Concrete used
Mix design for RCC was got done from "B. V. Bhoomaraddi College
of Engineering and Technology , Hubli. A compressive strength of
24.7 N/mm at 7 days and 40.57 N/mm at 28 days was achieved in
the design mix. Concrete cubes were tested at site duly establishing
the concrete testing machine. During the progress of casting of the
boxes, 156 cubes were tested for 7 days strength and 156 cubes for
28 days strength. Average strength of 35 N/mm for 7 days and 44
N/mm for 28 days respectively was achieved.
4.1 Design Mix
The mix design for M30 grade concrete is adopted for the RCC
work. The ratio of 1: 1.35: 2.58 was adopted as per mix design.
Water cement ratio was 0.42. In addition super plasticizer (SP430)
at 0.3 % (minimum) by weight of cement was used.
5.0 Procedure of Casting of RCC Box & Pushing Operation
z Install necessary temporary engineering indicators as per rules
in force.
z

Impose speed restriction of nonstop 20 kmph over proposed

bridge site.

5.1 Thrust Bed

Thrust bed is one of the important items of the box pushing technique.
The location and level should be carefully decided in such a way
that entire length of the box is pushed to the desired location. To
achieve the desired location of the box, the gap between the end of
the box and beginning of the thrust bed shall be kept 2 to 3m.
The thrust bed, thrust beam and keys are designed with RCC to
resist the required thrust exerted by jacking force and to transfer it
to soil at bottom and sides. In cohesive soils even shallow piles are
required to transfer the load. Provision for jacking supports is made
by providing suitable pockets in the bed to accommodate pin
supports. After completion of jacking the thrust bed is utilized as
floor bed and is left in place.

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Reinforcement detail of main & auxiliary thrust bed.

View of thrust bed after casting

5.2 Casting of Precast RCC Box Units

The precast box is cast in segments of convenient lengths. The box
section is designed as per IRS codes of practice for 25 T loading
2008.
First RCC box segment (leading segment) is cast over the well set
and leveled thrust bed. The front face of the box was cast in sloped
manner to match the shape of cutting edge and was integrated to
the concrete. The cutting edge was provided all around the box as it
acts as shield preventing falling of soil from top and sides. A steel
rear shield is also provided which houses and guides the subsequent
segments.

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5.3 Function of Front Cutting Shield

The first segment of the precast box was provided with a specially
designed structure named as cutting shield which formed the cutting
face with a cutting edge fabricated from 16 to 20 mm MS plates and
housed on RCC box section with suitable anchor bolts. The cutting
edge was provided with stiffeners at regular interval through the
face of box. On completion of jacking the outer shell of the shied
was cut and removed. The function of the front shield is to support
the soil on top and sides during jacking.
0.80
0.31
0.50

5.15

0.50

0.30
0.31

2.30

Fig. 4 : Side view of cutting edge

6.00

5.00

6.15

5.15

Fig. 5 : Front view of cutting edge

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Front Cutting Shiield

5.4 The function of Rear Jacking Shield

The rear jacking shield was provided by anchoring steel plate on
the face of the bottom slab of RCC box suitably designed to distribute
the jacking load uniformly on concrete area. The function of rear
shield is to house and guide the following segments. It also functions
as a hood for supporting the soil on top and sides between the two
units.
5.5 Intermediate Jacking Station
As total length of box is cast in segments, each segment is pushed
turn by turn with necessary jacking force. Necessary intermediate
jacking stations are provided with jacking pockets in bed & walls.
5.6 Pushing operation of the box
To reduce the frictional resistance, a thin film of grease and thick
gauge plastic sheets are provided between the top of the thrust bed
& bottom of the box. This is done before casting of the bottom slab
of the box. A glossy epoxy layer is also provided to reduce friction
on the top and prevent the distribution to the earth and ballast mass
over box during pushing operation.

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Provision of thick gauge plastic sheet over a thin film of grease

Where mass of embankment is less or the soil is of poor quality

drag sheet system is also considered for least resistance of friction
and disturbance to the mass above box.
DRAG SHEET CONSISTS OF GALVANISED
ALUMINUIM SHEET
IN ROLL, 1 MM THICK AND 0.90M WIDTH
STEEL PORTAL FOR
ANCHORING DRAG SHEET

DRAG SHEET 3
LAYERS, 4 ROWS

G. I PIPES SUPPORTING
DRAG SHEETS
20 MM SLOT 1.00 LONG
TO GUIDE DRAG SHEET
(SLOTS 4 NO.)

STIFFENERS
20 MM PLATE
BOX
SEGMENT

PILOT
SEGMENT

Fig. 6 : Drag Sheet Arrangmets

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CUTTING EDGE
WITH 20 MM
STEEL PLATES

Drag sheet arrangement over box

Drag sheet arrangement over box with anchoring portal

Auxiliary beds are also provided for casting of the other segments
with thin film of grease and plastic. Segments are then brought in
alignment of pushing as and when required as pushing progresses.
With the progress of jacking, the front unit with shield penetrates
into the embankment. There after excavation within the shield is
done either manually or mechanically and the excavated stuff is
transported outside the working area.
The progress of pushing is kept continuous and the system of shifting
of remaining box segments from auxiliary bed and bringing them
into alignment is adopted till total length is pushed.

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5.7 Hydraulic Equipment

Sufficient numbers of Jack units are provided in series for distribution
of pushing load evenly on the face of the concrete, and all jacks are
operated simultaneously with a common power pack, which supplies
uniform flow of pressure through network of hydraulic pipes
commencing from front unit to rear unit. Jacking force is applied in
sequence. The pushing cycles are repeated till total pushing is
completed.

Box segment

Box segment

6.15

Movement of box

20 mm plate embeded
in concrete

Jack 180 ton capacity

1.00

Fig. 7 : Position of jacks between segments

End box segment

Spacers
(steel)
Pin Pockets
0.6 x 0.6 x 0.6 size

6.15

Steel pin
Jacks 180 Ton capacity

20mm plate embedded in concrete

Thurst bed

2.50

2.50

2.50

Fig. 8 : Position of jacks on thrust bed

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Jacking of end segment of box from thrust bed

Jacking of intermediate box segment taking support

from adjoining box segment

6.0 Precautionary Measures for Successful Operation of Box

Pushing
6.1 Cutting edge of front shield is fabricated with adequate thickness
of steel plate and the front edges of the steel plate are sharpened
to facilitate penetration into the soil.
6.2 Cutting edge shall be projected more at the top with respect to
bottom slab to prevent falling of earth from top during excavation.

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6.3 Leading segment shall be pushed at least 10cm less than the
length of the rear shield in one operation.
6.4 To prevent caving of earth during excavation quantity of earth
shall be removed to barest minimum duly following the slop of
cutting edge.
6.5 Guide channels to be provided in the thrust bed to guide the
segments to ensure straight alignment.
7.0 Conclusion
The box pushing method adopted for elimination of this Level
Crossing is found suitable and convenient as per the site conditions.
Numbers of construction joints in this method are reduced compare
to cut and cover method. Requirement of Mega Line Block could
also be avoided by adopting this technique. Though the cost of
construction in this method is more, it is adopted mainly due to nonavailability of Mega Line Block and due to non-availability of longer
temporary girders (R. H. Girders). The box pushing work has been
successfully completed without disturbance to track as Drag Sheet
has facilitated for smooth insertion of Box through formation.

*****

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