Box Jacking PDF

International Conference on: Engineering: Issues, opportunities and Challenges for Development
ISBN: 978-81-929339-1-7
BOX JACKING - AS BENEFICIAL CONSTRUCTION TOOL :

PROBLEMS & REMEDIES
Ramani Hiren1, Jayeshkumar Pitroda2, J.J.Bhavsar3
First Year Student, ME C E & M., BVM Engineering College, Vallabh Vidyanagar, Gujarat, India 1
Assistant professor, Civil Engineering Dept., BVM Engineering College, Vallabh Vidyanagar, Gujarat, India 2
Associate professor, Civil Engineering Dept., BVM Engineering College, Vallabh Vidyanagar, Gujarat, India 3
Abstract: Box jacking, also known as Tunnel Jacking, involves the advancement of a site cast
rectangular or other shaped sections using high capacity hydraulic jacks. The structure to be
installed is constructed, normally in reinforced concrete, on a launch pad at a site adjacent
to where it has to be installed. It is then thrust forward horizontally using advance support,
open shield and jacking technology with excavation taking place from inside the box. This is
frequently used where an existing road or rail track existing on an embankment and space in
the structure to be cast on the side. There are variations on this concept using short pre-cast
units to form the box. Box jacking is jacking a large precast reinforced concrete box
horizontally through the ground, usually beneath a road or railroad that must not be
interrupted. The major advantage of the process is its essential simplicity. Only the exact
prism of earth that will be filled by the jacked box is excavated. No intermediate ground
supports are needed. The structure is built away from the roadway, in the clear, without the
constraints of shoring and traffic controls. When the structure is ready, a shield is fitted to
the front, hydraulic jacks are installed behind, and the box is pushed into final position while
Simultaneously the earth is excavated from within. The actual jacking generally takes only a
few days to a week. During that time, traffic is proceeding overhead normally, unaware of the
construction below. The non-disruptive nature of the process together with its inherent safety,
simplicity and economy make box jacking a useful tool for the practicing civil engineer. This
paper intends to bring a greater familiarity with the box jacking process to the reader and
then give some considerations and guidelines to assist engineers in designing a project that
can be built using the box jacking method. Box jacking is a well-established means of
engineering culverts or tunnels under rail embankments or waterways to accommodate road
or rail traffic. It is a way of overcoming or circumventing geophysical impediments in order
to build a road or rail networks. Many tunnels of note around the world have been built using
the box jacking process and though technology has improved greatly in recent times the
engineering capacity has been around for quite a while. From a technical viewpoint the box
11th April, 2015, S.N. Patel Institute of Technology & Research Centre, Umrakh, Bardoli
ISBN: 978-81-929339-1-7
jacking process begins with the excavation of a launch area or sink pit where a secure
backdrop can be constructed to facilitate the hydraulic jacking rams that will push the precast concrete box sections into place. These large concrete boxes are custom constructed on
site to suit the size of the tunnel. Once built they are hydraulically jacked into position with
an excavator digging out the spoils at the face and removing it for disposal. As the
excavation proceeds the concrete section is pushed slowly into position to form the roof, floor
and sides of the tunnel.
Keywords: box jacking, precast, box pushing, culverts.

I.
INTRODUCTION
A. Definition
Box jacking is jacking a large precast reinforced concrete box horizontally through the
ground, usually beneath a road or railroad that must not be interrupted. The major advantage
of the process is its essential simplicity. Only the exact prism of earth that will be filled by
the jacked box is excavated. No intermediate ground supports are needed. The structure is
built away from the roadway, in the clear, without the constraints of shoring and traffic
controls. When the structure is ready, a shield is fitted to the front, hydraulic jacks are
installed behind, and the box is pushed into final position while simultaneously the earth is
excavated from within.
B. Overview of box jacking
Box jacking is a well-established means of engineering culverts or tunnels under rail

embankments or waterways to accommodate road or rail traffic. It is a way of overcoming or
circumventing geophysical impediments in order to build a road or rail networks. Many
tunnels of note around the world have been built using the box jacking process and though
technology has improved greatly in recent times the engineering capacity has been around for
quite a while. From a technical viewpoint the box jacking process begins with the excavation
of a launch area or sink pit where a secure backdrop can be constructed to facilitate the
hydraulic jacking rams that will push the precast concrete box sections into place. These large
concrete boxes are custom constructed on site to suit the size of the tunnel. Once built they
are hydraulically jacked into position with an excavator digging out the spoil at the face and
ISBN: 978-81-929339-1-7
removing it for disposal. As the excavation proceeds the concrete section is pushed slowly
into position to form the roof, floor and sides of the tunnel. Box jacking requires high
pressures to push the concrete boxes into place and a series of hydraulic rams is used to
accomplish the task. Large cutting heads such as are used with tunnel boring machines do not
form part of the box jacking procedure. The excavator performs the task of removing the clay
soil or rock from the face as the concrete section is rammed slowly forward to form the
tunnel casing. The backdrop against which the jacking rams rest is constructed with concrete
filled sheet pile shuttering. This ensures a strong enough backdrop against which the jacking
rams can operate to jack the concrete sections into place. This procedure is used for larger
tunneling projects and can be performed quite quickly once the concrete sleeve or box has
been constructed on site. Box jacking requires a minimal number of operatives and is
therefore cost-effective from a labor point of view.
Box jacking is jacking a large precast reinforced concrete box horizontally through the
ground, usually beneath a road or railroad that must not be interrupted. The major advantage
of the process is its essential simplicity. Only the exact prism of earth that will be filled by
the jacked box is excavated. No intermediate ground supports are needed. The structure is
built away from the roadway, in the clear, without the constraints of shoring and traffic
controls. When the structure is ready, a shield is fitted to the front, hydraulic jacks are
installed behind, and the box is pushed into final position while simultaneously the earth is
excavated from within. The actual jacking generally takes only a few days to a week. During
that time, traffic is proceeding overhead normally, unaware of the construction below. The
non-disruptive nature of the process together with its inherent safety, simplicity and economy
make box jacking a useful tool for the practicing civil engineer. This paper intends to bring a
greater familiarity with the box jacking process to the reader and then give some
considerations and guidelines to assist engineers in designing a project that can be built using
the box jacking method.
C. History of box jacking
A year ago when the concrete is not used for the construction there was a stone which is used
for the making of the tunnels and boxes which is used for the construction of the highways or
bypasses. And also when the pile is not invented we are using the deep foundation rather than
the pile foundation. But now a day, technology is upgraded and we have a latest technology
in construction industries. so nowadays we first prepare the precast boxes and piles and then
ISBN: 978-81-929339-1-7
after using the jacking system we place them into the right position and very quick to
compare the old days.
Below figure 1 and 2 shows the previous tunnel condition and latest tunnel condition
Figure 1: tunnels without box culverts

(Source: http://driverlayer.com/img/tunnel/142/image?tab=1)
Figure 2: latest tunnels using box culvert

( Source: http://www.ice.org.uk)
D. Advantages of box jacking

1. Better quality control.
2. Economical.
3. Time of completion is less.
4. Saving in man power & Machinery.
5. No involvement of crane & heavy equipment.
6. Less involvement of other Departments.
ISBN: 978-81-929339-1-7
E. Disadvantages of box jacking

1. Needs trained staff and skilled supervision.
2. Imposition of caution order exists for a longer period.
3. No scope of the night working.
4. Once the vertical & the lateral alignment of box disturbed it becomes almost
impossible to rectify it.
II.
LITERATURE REVIEW
A. General description
In principal, box jacking is very simple. The box is built on a greased launch slab Lined up
exactly with its final location. It is then pushed straight ahead, guided by curbs On the left
and right to slide straight off the launch slabs. A steel shield installed on the Front cuts the
hole with minimal overcut. The force of the jacks is usually reacted against the earth at the
back of the jacking pit but this is not absolutely necessary. A box could theoretically be
pulled into place. During jacking, lubricant is pumped around the box to ease its passage
through the ground. Upon reaching final location, grout is injected to displace the lubricant
and permanently support the overlying ground. The box is best precast in one large block to
the full length required. This is optimal, as rigidity and accuracy can be fairly guaranteed.
Where space is limited the box can be cast in halves, thirds, or even more pieces. Although
this reduces the total length of thrust column required, it introduces the requirement of
employing great care in constructing subsequent box sections to make sure they are exactly
aligned with the initial pieces. The box jacking process can be described in terms of its
constituent subsystems, more critical and primary of which is dimensioned. The box must
closely fill the hole being cut by the shield at the front, and obviously, not even slightly,
overfill it.
The mechanical subsystems are as follows:

Jacking - backstop, thrust columns, hydraulic pumps, and jacks
Excavation - shield, face control, digging equipment, transport.
Ventilation - gas testing, fans and fanline.
Lubrication - mixers, pumps, distribution piping and manifolds.
Guidance - lasers, levels, steering provisos.
ISBN: 978-81-929339-1-7
These systems, acting in concert, can propel the heaviest concrete structure straight into the
ground, producing a complete installation with maximum ease and economy. To realize these
potential benefits it is very helpful if the project is originally designed with box jacking in
mind.
B. Box modifications:
Generally, only one dimensional modification is done and that is to add thickness to the walls
and invert slab so that the thrust of the jacks is backed up by plenty of concrete. Additional
repair, such as stirrups can be added in the local high stress area where the jacks push on the
concrete. The box must be made accurately. This is probably the most critical point in the
whole process. If the box has high spots outside the design line the force required to push it
can be significantly increased.
Overall, the essential subsystems can be outlined thus:
1. Site preparation access, dewatering, etc.
2. Jacking pit Shoring and reaction wall Launch slab
3. RC Box and adaptation for jacking
a) Dimensional modifications and extra rebar.
b) Extra close external tolerances
c) Shield on front
d) Embeds for lubricating slurry distribution
e) Pressure cells and instrumentation
f) Grout holes
4. Jacking System Jacks, Hydraulic pumps, plumbing, oil reservoir, Thrust columns to
backstop Material Handling
5. Excavation System
a) Face excavation
b) Muck Transportation to Shaft
c) Removal from Shaft
6. Ventilation System
7. Guidance System
a) Steering Provisos
b) Lasers
8. Communication Systems
ISBN: 978-81-929339-1-7
III. STEPS FOLLOWED IN BOX JACKING
1. Launch slab - looking towards the backstop

2. Launch slab looking at portal wall
3. Applying grease to launch slab
4. Slurry piping & rebar in box walls
5. Casting roof & walls of box
6. Shield enters the ground
7. Adding thrust columns after jacking
8. Mucking tunnel
9. Jacking completed
IV. PROBLEMS ENCOUNTERED DURING BOX JACKING
a) Tilting of box.
b) Shifting of longitudinal alignment.
c) Failure of pin pocket.
d) Leaking of joints.
e) Occurrence of boulder layer.
f) Occurrence of hard rock.
g) Occurrence of collapsible strata.
h) Unexpected floods during box pushing.
i) Disturbance in track geometry.
A. Tilting of box.
Effects
1. Differential earth cushions above box.
2. Creation of gap between two segments.
3. Lifting of track adversely.
4. Reduction in space for ballast wall construction.
5. Excessive resistance in pushing subsequent segment.
ISBN: 978-81-929339-1-7
Remedies
1. Obstruction against cutting edge to be removed during pushing.
2. Preferably pushing should be 300mm at a time.
3. Proper fixing of metal sheet at rear end of segments.
4. Differential jacking to rectify tilt.
5. Fix the reference points to check the vertical and lateral alignment regularly.
B. Shifting of longitudinal alignment.
Effects
1. Pressure on jacks on one side will increases abruptly may cause failure of jacks.
2. There will be a gap creation at the junction of two boxes.
3. Road becomes skew may lead to damage through the hitting of box by vehicles .
Remedies
1. Reference pegs to be fixed with respect to the center line of the box.
2. Regularly checking the longitudinal alignment.
3. Differential jacks to rectify the longitudinal alignment.
C. Failure of pin pocket.
Precautions
1. The concrete shall be dense & properly compacted.
2. Entire concrete to be cast in one go.
3. M.S. Sheet of adequate thickness to be provided with pockets.
D. Leaking of joints
Precautions
1. M.S. Plate to be provided at the top of the junction of two boxes.
2. Epoxy grouting to be done from inside.
ISBN: 978-81-929339-1-7
E. Occurrence of boulder layer
Effects
1. Hindrance in pushing hence more time consumption.
2. Excessive pressure affects efficiency of jacks.
3. Obstruction to cutting edge.
4. Disturbance in track geometry.
5. Ballast get through the voids between boulders and drop down results hanging
position of sleepers in unsafe condition.
Remedies
1. Excess ballast unloading at site.
2. Boulder removed segments to be protected by providing gunny bags filled with sand
simultaneously.
3. Preferably pushing carried out under traffic block.
4. Removal of boulders manually to be tackled in small segments of entire width.
5. Stabilizing of sub grade by using betonite power.
F. Occurrence of hard rock
Effects
1. Manual excavation becomes ineffective.
2. Slow process affects the entire progress.
3. Bending of cutting edge.
4. Failure of jacks due to excessive pressure.
5. Tilting of box / deviation in alignment.
Remedies
1. Controlled blasting may be resorted to.
2. Mechanical arrangement like compressors, pavement breaker, splitters, etc. is
required.
3. Cutting edge should be designed as per site conditions.
ISBN: 978-81-929339-1-7
G. Occurrence of collapsible strata
Effects
1. Settlement of the track.
2. Safety hazards during passage of traffic.
3. Cautious & slow process.
4. Sudden collapse of sub grade.
Remedies
1. In case of collapsed bank RH girders to be provided.
2. Smallest length to be attempted during pushing.
3. Stabilization of sub grade with Betonite.
4. Arrangement of CC cribs and girders at the site to deal with emergencies.
5. Frequent recoupment of Ballast & track attention.
6. Sufficient numbers of gunny bags filled with sand kept ready.
H. Unexpected floods during box pushing
Effects
1. Submergence of machinery interrupts the process.
2. Excessive friction due to wet soil mass.
3. Damage to the slope of the banks.
4. Disturbance to cess requires protections.
5. Collapse of bank due to water current & heavy rain.
Remedies
1. Shoring arrangements to be made available.
2. Revision of caution orders as per site conditions.
3. Unloading of Boulder / quarry dust rake for bank protection.
4. Water pumping arrangements along with provision of coffer dams.
5. Sufficient numbers of gunny bags filled with sand kept ready.
10
ISBN: 978-81-929339-1-7
I. Disturbance in track geometry
Effects
1. Bulging of side slopes.
2. Abrupt cross level variation.
3. Shifting of earth mass along with the box.
4. Resulting in deficiency of ballast requires frequent recoupment
5. Lateral shifting of the alignment.
Remedies
1. Recording of track parameters & frequent attentions.
2. Arrangement of Tirfors to resist the movement of track along with the box.
3. Unloading of sufficient ballast well in advance.
4. Epoxy paints on the top surface use of the drag sheet to reduce friction.
5. Daily pushing without interruption to avoid frictional resistance.
6. Counter weight on the exit end of bank.
7. Deployment of sufficient labour to correct the disturbed track structure.
V.
CONCLUSION
From the literature review, it is concluded that, the comparison to the years ago technology in
construction world was quite developed. So then we construct the tunnels and over-bridges
using the box culverts its very rapid and the cost of construction is less and there is less risk
And pushing technology is widely used nowadays and gives very good results of work.
a) Box pushing work requires close supervision and monitoring, and quite often the unsafe
conditions to develop at these sites.
b) The track must be watched regularly to see signs of heaving, settlement, misalignment
etc.
c) Work must be done under block protection / caution order only.
d) Box pushing work means at least partly working with blind, so problems usually come up
during execution of work.
e) LWR (Long Welded Rail) must be cut and site isolated during box pushing.
11
ISBN: 978-81-929339-1-7
ACKNOWLEDGEMENT
The Authors thankfully acknowledge Dr. C. L. Patel, Chairman, Charutar Vidya Mandal,
Er.V.M.Patel, Hon. Jr. Secretary, Charutar Vidya Mandal, Dr. F.S.Umrigar, Principal, BVM
Engineering College, Dr. L. B. Zala, Professor and Head, Civil Engineering Department,
BVM Engineering College, Prof. J. J. Bhavsar, Associate Professor and P.G. Coordinator
(Construction Engineering and Management), B.V.M. Engineering College, Mr. Yatinbhai
Desai, Jay Maharaj construction, Vallabh Vidyanagar, Gujarat, India for their motivations,
infrastructural support and cooperation to carry out this research.
REFERENCES
[1] Anthony Lynn, Berkeley Engineering Company, Inc. Box-Jacking - A Useful Construction Tool 4th
International Engineering and Construction Conference - July 28, 2006
[2] Allenby, D. & Ropkins, J.W.T. 2004. The use of jacked box tunnelling under a live motorway to form a
vehicular underpass. Geotechnical Engineering 152, Issue GEI, October 2004: 110.
[3] Bing-bing TU, Dong Zhao, Yan-Qiang Zhang Application of the Foundation Underpinning by Manual
Pipe-Jacking in the Conservation of the Masonry Ancient Construction 2013, EJGE
[4] B. Tripathi, K. K. Choudhary, V. K. Khare, Box Pushing Technique: Problems and Remedial Measures
[5] Chen, J., Ma, Y., Jeng, T. And Chang, C., 2010. An assessment of user needs for intelligent living space.
Intelligent Buildings International, 2 (1), pp. 20-40.
[6] Douglas Allenby & John W.T. Ropkins Creating underground space at shallow depth beneath our cities
using jacked box tunnelling IAEG2006 Paper number 62
[7] http://www.jackedstructures.com/box-jacking.html
[8] http://www.jackedstructures.com/box-jacking.html
[9] http://driverlayer.com/img/tunnel/142/image?tab=1
[10] http://www.ice.org.uk
[11] http://www.fhwa.dot.gov/bridge/tunnel/pubs/nhi09010/12.cfm
[12] http://www.nrcresearchpress.com/doi/abs/10.1139/cgj-2012-0334
[13] http://www.thiess.com.au/news/2011/largest-jacked-box-operation-in-australia
[14] http://www.constructionworld.in/News.aspx?nId=JjDft4lL3daEe1VT5gZ7Tg
[15] J.W.T. Ropkins, D. AllenbyChappells, Underground Space Use: Analysis of the Past and Lessons for the
Future Erdem & Solak (Eds) 2005 Taylor & Francis Group, London, ISBN 04 1537 452 9
[16] Ropkins, J.W.T. 1998. Jacked box tunnel design and construction. In ASCE (ed), Proceedings of the
Sessions of Geo-Congress 98, Special Publication No 87, Boston, 1998, Boston: ASCE.
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ISBN: 978-81-929339-1-7
AUTHORS BIOGRAPHY
Hirenkumar D. Ramani was born in 1993 in bhayavadar town. He
received his Bachelor of Engineering degree in Civil Engineering
from the Birla Vishvakarma Mahavidyalaya engineering college,
Gujarat Technological University, in 2014. At present, he is First
year student of Master's Degree in Construction Engineering &
Management from Birla Vishvakarma Mahavidyalaya, Gujarat
Technological University.
Prof. Jayeshkumar R. Pitroda received his Bachelor of Engineering
degree in Civil Engineering from the Birla Vishvakarma
Mahavidyalaya, Sardar Patel University in 2000. In 2009 he
received his Master's Degree in Construction Engineering and
Management from Birla Vishvakarma Mahavidyalaya, Sardar Patel
University. He joined Birla Vishvakarma Mahavidyalaya
Engineering College as a faculty in 2009, where he is Assistant
Professor of Civil Engineering Department with a total experience
of 14 years in the field of Research, Designing and education. He is
guiding M.E. (Construction Engineering & Management) Thesis
work in the field of Civil/Construction Engineering. He has
published many papers in National Conferences and International
Journals.
Prof. Jaydevbhai J. Bhavsar received his Bachelor of Engineering
degree
in
Civil
Engineering
from
the
Birla
VishvakarmaMahavidyalaya, Sardar Patel University in 1978. In
1986 he received his Master's Degree in Building Science and
Technology from University of Roorkee. He joined Birla
VishvakarmaMahavidyalaya Engineering College as a faculty
where he is an Assistant lecturer of Civil Engineering Department
with a total experience of 32years in the field of Research,
Designing and education. He is guiding M.E. (Construction
Engineering & Management) Thesis work in the field of Civil/
Construction Engineering. He has published many papers in
National Conferences and International Journals.
13

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International Conference on: Engineering: Issues, opportunities and Challenges for Development

BOX JACKING - AS BENEFICIAL CONSTRUCTION TOOL :

Keywords: box jacking, precast, box pushing, culverts.

B. Overview of box jacking

Box jacking is a well-established means of engineering culverts or tunnels under rail

Figure 1: tunnels without box culverts

Figure 2: latest tunnels using box culvert

D. Advantages of box jacking

E. Disadvantages of box jacking

The mechanical subsystems are as follows:

1. Launch slab - looking towards the backstop

B. Shifting of longitudinal alignment.

C. Failure of pin pocket.

E. Occurrence of boulder layer

F. Occurrence of hard rock

G. Occurrence of collapsible strata

H. Unexpected floods during box pushing

I. Disturbance in track geometry

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