= aa aan ~ ta area aan Kailash Singi ——— agar aires ate are ToT sara Rie worTs; — 226011 Government of India - Ministry of Railways Research Designs & Standards Organisation Executive Director / Structures ee orkory Prear@ / wer Saas ‘mall: edstricturestigmatlcom No. CBS/Box Pushing Dated: 19.12.2017 26 ‘The General Manager (Engg.), Central Railway, Mumbai CST-400 001. Eastern Railway, Fairlie Place, Kolkata-700 001. East Central Railway, Hazipur- 844 101. East-Coast Railway, Bhubaneshwar- 751 016. Northern Railway, Baroda House, New Delhi- 110 001. North-Central Railway, Allahabad- 211 001. North Eastern Railway, Gorakhpur-273 001. North-Western Railway, Jaipur-302 001. Northeast Frontier Railway, Maligaon, Guwahati-781 061. 10.Southern Railway, Park Town, Chennai-600 003, 11. South Central Railway, Rail Nilayam, Secunderabad-500 371. 12.South East Central Railway, Bilaspur- 495 004. 13.South Eastern Railway, Garden Reach, Kollata-700 043 14. South-West Railway, Hubli 580 023. 15. Western Railway, Mumbai-400 020. 16. West-Central Railway, Jabalpur 482 001 PEN ggseNe Sub: Guidelines for construction of Road Under Bridge by Box Pushing technique (Item no. 1040 of 84% BSC Meeting). Ref: Railway Board letter no. 2017/CE-IV/ROB/RUB/LHS/LC (BSC) dated: 14.12.2017. As discussed in 84% BSC Meeting vide item no. 1040 and as advised by Board, guidelines were prepared for construction of RUB by box pushing method, Board has approved technical guidelines on box pushing technique vide reference above. A copy of guidelines has been uploaded on railnet site (10.100.2.19 -> Bridges and Structures Directorate -> RDSO’s letters to Rlys). These guidelines can be used for box pushing in case it is resorted to, in exceptional circumstances, keeping in view the extant instructions issued vide Board’s letter no. 2014 /CE-III/BR/ Bridge Policy dated: 29.05.2015. In case of any difficulty during execution, the issue may be referred back to RDSO for further action. DA: Nil. (Kailash Singoy'/? ies Executive Director /Structures B&S Directorate RDSO Copy to: A. General Manager (Construction), Construction Organization, N.F. Railway, Maligaon, Guwahati. B.. Executive Director Civil Engg./B&S, Railway Board, Rail Bhawan, Room No.140A, New Delhi-110001. G: Director, Indian Railway Institute of Civil Engineering (IRICEN), Pune-410 001,D. The Chief Administrative Officer (Constn.): oy sepr Central Railway, Mumbai CST-400 001 Eastern Railway, Fairlie Place, Kolkata-700 001 Central Railway, Mahendrughat, Patna (Bihar)-800 004. East Coast Railway, Bhubaneswar, (Orissa) 751 016 Northern Railway, Kashmere Gate, Delhi-110 006. USBRL Project, Northern Railway, Satyam Complex, Trikuta Nagar Extn., Jammu-180 020. North Central Railway, Allahabad, (U.P.). North Eastern Railway, Gorakhpur-273 001. North Western Railway, Jaipur, (Rajasthan) 482 001 . Southern Railway, 183, Periyar High Road, Egmore, Chennai - 600 008 South Central Railway, DRM/Secunderabad Office Compound, ‘Secunderabad-500 371. South Eastem Railway, Garden Reach, Kolkata-700 043 South East Central Railway, Bilaspur 495 004 . South Western Railway, No. 18 Miller Road, Bangalore, (Karnataka) 560 046 . Western Railway, Mumbai-400 020. 3 West Central Railway, Jabalpur. (M.P.) 482 001 . Southern Railway, Karshaga Road, GCDA Complex, 1* Floor, Ernakulam, Kerala- 682 012. ovds 7 2-1 (Kailash sig) 9 Executive Director/Structures B&S Directorate RDSOGOVERNMENT OF INDIA MINISTRY OF RAILWAYS GUIDELINES FOR CONSTRUCTION OF SUBWAY BY BOX PUSHING METHOD DEC-2017 BRIDGE & STRUCTURES DIRECTORATE RESEARCH DESIGNS AND STANDARDS ORGANISATION LUCKNOW ~ 226011CONTENTS SI. No. Description Page No. 7, | introduction 7 | 2. Box Pushing Technique cs 4 | 3. | Guidelines on Box pushing works 47 “4. | Problems likely to be encountered in box pushing method 72FOREWORD Indian Railway is constructing large number of Subways/RUBs for elimination of level crossings from the system or due to other needs. The work is mainly executed by ‘cut and cover’ method. RDSO has also issued typical drawings for Subways. Guidelines for construction of RCC Box subway/bridge by cut and cover method have already been issued. As per Railway Board letter No. 2014/CE-IIVBR/Bridge Policy dated 29.05.2015, a direction was issued to Zonal Railways to construct the subway/RUB preferably by using relieving girders to the extent possible and in exceptional circumstances to use Box Pushing Technique, that too, with the personal approval of PCE/CAO/C concemed. Board has further directed RDSO to prepare technical guidelines for Box Pushing Technique as per BSC item No. 1040/84" communicated vide letter No, 2016/4/CE-IIVBRIBSC/84/seminar dated 21.03.2017 The “box pushing” method for construction of Subway/RUB is also one of the methods being used in the field for long time. This method does not require any traffic block and work can be carried out duly imposing suitable speed restrictions. In order to maintain the uniformity and safe working in the field, guidelines on construction of Subway/RUB by “Box Pushing” technique have been prepared duly incorporating the comments received from Zonal Railways, covering all issues being confronted during execution of work in the field It is expected that these guidelines will serve as a technical guidance for officials of Engineering Department of Indian Railways working in the field. Lucknow Dated: 19.12.2017 (kaiasn sin) ve Executive Director/Structures B &S Directorate, RDSOGUIDELINES FOR CONSTRUCTION OF SUB-WAY BY BOX PUSHING METHOD 1.0 Introduction: A large number of RCC boxes are being constructed in railway system for use as Sub-way/RUB for elimination of level crossings or due to other needs, The verious methods being adopted in construction of RCC boxes for sub-ways, generally, are: ()— Castin-situ (i) Cutand cover method (ill) Using RH Girder (iv) Box pushing method Construction of sub-way(using RCC Boxes) by Box pushing method is sultable where Sonstruction of RUB is not practicable or suitable with other types of construction ie. in, Situ casting, cut and cover method (requiring long tratfic blocks or hindrances in electrified The various advantages of this technique include: * uninterrupted traffic movement * better quality control * no requirement of cranes and heavy equipment eto However, there are some specific considerations to be addressed before going for this Technique ie. * higher cost * highly skilled supervision + speed restriction for longer time * chances of slipping of soll mass from top without any signal, creating unsafe conditions etc. ‘condition permits. The various features of BOX PUSHING technique include: oto coyfitust Bed: Pre Cast RCC Box segments are constructed and pushed over a concrete apron called thrust bed. Thrust bed provides reaction frame against which the jacks push the BON Segments. To ensure that adequate resistance against slipping is available, thrust bed has sheer 1keys underneath which provide grip with the sub-grade. The site specific data for soil properties is used as basic data for the design of Thrust Bed. Since Box is pushed over thrust bed, the top surface of the same must be level. Thrust Bed & Pin Pockets Pin Pocket: To provide reaction, cubical holes are provided in the thrust bed, called pin pockets. Vertical beams are provided in the pin pockets which give reaction against which the segments are pushed. Hydraulic jacks are used to push the segments against these pin pockels. Since jacks have small ‘throw’ or maximum distance of push, packing pieces need to be provided between the jack and the pin pocket as the segment moves forward. A series of pin pockets are provided so that as soon as pin pocket is cleared by the segment, the same can be used for taking reaction. / | Jacks for pushing Packing pieces which are provided between jack and pin pocket Beam inserted in Pin Pocket (Being used for pushing) H Pin Pocket (Not in use) | eis cpennaneeret General arrangement of pushing arrangement 22.2 Cutting edge: Cutting edge is provided in the front so that resistance is minimum while pushing. It is fabricated with MS plates and housed on RCC Box section with suitable anchor bolis. Necessary strengthening is provided by stiffeners and face plates of Box in front. It also supports the soil in front of the Box up to certain distance. Soil below cutting edge is removed. The soil thus removed provides a void in front of the BOX into which the BOX is pushed. Cutting edge installed in front of a Box 2.3 Jacks for Pushing: The pushing work is done using hydraulic jacks. High capacity jacks are required with higher throw so that more pushing can be accomplished in single placement of Jacks. Two or more jacks are used to push the Box. The jacks push near the bottom of BOX taking reaction from the pin pockets installed in the thrust bed. To ensure uniform pushing effort on all jacks, synchronous jacks operated by a single power pack are generally used. 2.4 Stages in BOX pushing: Before starting the Box pushing, the track is to be Converted into SWR and should be supported by providing suitably designed Rail Clusters. ‘The BOX pushing operation is done with the following stages: 2, Casting of thrust bed: First, the thrust bed is cast near the location of Box pushing. The thrust bed shall be constructed outside the embankment so that there is no disturbance to the running traffic. b. Casting of BOX segments: The BOX segments are cast on the thrust bed or on a separate bed i.e. auxiliary bed or casting bed (prepared either in longitudinal direction or in lateral direction depending on the availabilty of land at site and working convenience). Installation of Cutting edge: A cutting edge, fabricated from 16 to 20 mm thick M.S. Plates, is installed in the first segment. d. Pushing work: The various stages involved in pushing ar i. Checking alignment of BOX segment to verify that itis proper. ii. Installation of beams in pin pocket. ili, Installation of jack between the BOX segment and vertical beam. iv. Operation of jack to push the BOX segment into the soi til its ram is completely out. v. Removing the jack.e 3. vi. Inserting suitable packing pieces and re-providing jack such that it can push the BOX segment again. vii, Repeating steps iv to vitil the BOX segment has gone inside the soil for @ length équall to the projection of the cutting edge beyond the top of the BOX segment. viii. Removing soil in front of the BOX, taking care that the soil in front of the cutting edge does not collapse. ix. After complete removal of soil, checking the alignment and level of the BOX segment pushed. If the same is OK, repeating steps ii to vill. The nearest available pin pocket is to be used for taking the reaction for pushing. x. After the first BOX segment has been pushed off the thrust bed, bringing the next BOX segment on to the thrust bed and joining the same with the first BOX segment suitably. xi. Pushing the complete assembly of BOX segments already inserted in track in a manner similar to the one described above, and so on, till all segments are inserted and the first ‘segment reaches its final location. The various stages in Box pushing are carried out in sequence one after the other such that the various inputs i.e. labour and machinery are optimally utilized, Balance Works: Removing the cutting edge and Construction of wing walls, return walls and road etc. as per the requirement. Compieted RUB Guidelines: Box pushing works need meticulous planning and safety precaution to avoid any disruption to traffic. Following items need to be kept in view while planning the Box pushing method: 34. 3.2. General Arrangement Drawing (GAD), Structural drawings of RCC Box segment and Thrust bed /auxiliary bed or casting bed should be prepared. These shall be approved by CBE of Railway. Locations of underground and overhead utilities and services lines, OFC, trees etc. which are likely to be affected, shall be . SBT cables, water pipe icated, in the GAD.38, 34. 35. 3.6. 37. 3.8. 39. 3.10. Concerned departments/authorities should be advised to take action to shift or protect them, during pushing operation. CRS Sanction to be obtained for Box pushing method indicating the detailed procedure to be adopted along with speed restriction to be imposed, if any, and safety precautions to be taken, Soil exploration to be done at the site of Box pushing, to know the soil type likely to be ‘encountered in Box pushing. Box pushing be planned if, good soil and soft! weathered rocks available. Pushing in hard rock or clay strata or black cotton soil should be avoided. Box pushing in cohesion less sandy soils should also be avoided. Preventive measures should be planned in advance i.e. grouting with cement, lime, fly ash, soil nailing, or any other soil stabilizing chemical, drag sheet, rail cluster etc. depending upon the type of soil, to avoid disruption to running traffic during Box pushing operations. Box pushing should not be adopted in case, there is possibility of sub soil, water seepage. There should normally be 1.0 m earth cushion available above top surface of Box, upto formation level. However, more is cushion safer will be pushing operation. The LWRICWR track should be converted into single rails with fish plated joints. The position of rail joints should be staggered away from the location of Box pushing so that the effect of increased wheel impact (due to rail joint) may be dampened to the extent possible, Buffer Rails/SEJ be provided in approaches to avoid buckling of track and/or rail fracture. Provisions of LWR Manual be followed while executing rail cutting, de-stressing of LWR & converting single rails to again LWR after the work is over. Thrust bed shall be properly designed. The failure of thrust bed during Box pushing operation may lead to serious problems/imposition of speed restriction for quite long period. If the space is not the constraint then preference should be given to design & provide the longer thrust bed. The longer length of thrust bed provides additional space for casting of RCC Box segments. The Thrust bed and Auxiliary bed (casting bed) location should be finalized keeping availability of Railway land in view. The size of the casting bed should be Such, $0 as to ensure continuous supply of Box segments during pushing. To reduce the frictional resistance, a thin film of Grease and thick gauge plastic sheet is to be provided at the top of the thrust bed before casting of Box segment. This should be done before casting of the bottom slab of Box. Alternatively, rails may be embedded in thrust bed. ‘A smooth Epoxy layer may be provided to reduce friction on the top of Box segment. This will also help to prevent the disturbance of the soil mass over Box during pushing. Cutting edge should be adequately designed (16-20mm thick MS plate) for taking load of traffic moving on the top. Adequate length of cutting edge (approximately 1.5 m) should be provided. Steel plate be also provided on the face of bottom slab of RCC Box to distribute the jacking load uniformly on concrete area (Rear and Front Jacking Shield). Fixing of cutting edge and back cover shield should be done with utmost care and accuracy so as to avoid any mal-functioning during the progress of Box pushing. Casting of first segment can bbe done in tapered section to follow cutting edge, profil. Jacks and power pack should be checked and inspected before commencing pushing operations. The hydraulic jacks to be used for Box pushing should be checked for their opening in one go. The hydraulic jack should have adequate opening so that the required3.11. 3.12. 3.13. 3.14, 3.15. 3.16. 3.17. 3.18, 3.19. pushing (20 to 30 cm) can be done comfortably in one setting of jacks. Standby jacks and adequate spares along with hydraulic oll should be arranged for jacks. To reduce the requirement of pushing force and also to reduce the disturbances to overlaying mass and so to the overlaying track particularly when cushion is less or the soil is of poor quality, drag sheet system may be considered, for least frictional resistance and disturbance of mass above Box. Altematively, lubrication of the surrounding soil may be done by using bentonite slurry. For this, RCC Box segments are required to be provided with 1” dia through holes (across the thickness of wall & slabs) at around 1. meter centre to centre. Through these holes, bentonite slurry is injected under pressure before and during the operation of pushing. After completion of pushing the holes should be grouted suitably. Box pushing shall be done only after concrete has attained the characteristic strength and in presence of P-way supervisor, who has sufficient experience of the work. Pushing Work should normally be done in day light hours. Pushing should be done when there is no train. Box pushing should not be done during Rainy season. Speed restriction should be imposed as planned. Pushing should be done in parts of 10 to 15 om at a time. The actual quantum of pushing to be done at a time shall be decided by site in charge based on disturbance being caused to track during each push. Alignment should be controlled during pushing by applying corrective forces. Directional corrections can also be achieved effectively by differential cutting of earth on sides i.e. more ‘on one side and less on other side. Measurements be done for alignment and level to ‘ensure that Box is not tilted or misaligned. Lookout P-way men shall be posted at site with banner flags and other protection equipments, when Box Pushing is in progress. These men should have the equipment of Observing variations in cross levels of track and should stop traffic, the moment any unsafe condition is noticed. P.way supervisor and adequate labour along with required tools/machinery should be available at site for attention to track during day and at night time. Cross levels and alignments are to be checked before passage of each train, record be maintained in register and corrective action be taken, if required. Proper lighting arrangements should be made during night time to inspect and maintain the track. Disturbance in track geometry should be monitored regularly and track defects should be rectified till track attains its original geometry. After completion of Box pushing work, proper sealing and grouting of joint should be ‘ensured. Concreting of jacking slots/ pockets in Box is done and construction of other Boxes on both approaches with wing wall/retum walls etc. is completed as per approved drawings. Speed restrictions should be relaxed as per IRPWM guidelines for deep screening work or a8 approved in drawings. Continuous manning of the site after completion of work should be done for at least 07 days to look for any settlement, cross-level going out, etc. A register should also be kept for recording the observations.<< 3.20. As soon as the first rainfall occurs after completion of the work, SSE/SE/JE(P.Way) should Visit the site and inspect for any unusual occurrence like settlement, loose packing, cross level going out, etc. Suitable speed restriction should be imposed as deemed necessary. 4, Problems likely to be encountered in Box pushing method: ire of Thrust Bed or pin pockets: If the design of thrust bed and or pin pockets and is not done properiy, the same may fail during Box pushing work with no easy solution. If the Box is partly on the thrust bed, repairs to the failed bed will be difficult and in absence of repairs, pushing of Box is not possible. 4.2. Misalignment of Box segments: In the Box pushing work pushing has to be done in stages. This working from part to whole can lead to magnification of errors in alignment control. Thus after each round of pushing, the Box alignment laterally and vertically needs to be verified. If itis found that the Box is deviating from its proper position, action for rectification needs to be taken. The misalignment may also be caused due to geological and other reasons. The other reasons which can lead to misalignment include: i, Poor soil, leading to sinking of Box downwards. ji, Obstructions under the Box such as stones, rock outcrop or other hard obstruction leading to upward movement of Box . i. Different soils in the Box alignment can lead to differential movement of Box. iv. Non-uniform removal of soil in front of Box. v. Non-uniform application of force from jacks - either due to eccentricity in jack placement or due to multiple jacks not acting in syne with each other. 4.3. Failure of Cutting edge: due to too much pressure on the cutting edge and improper design of the same, there can be buckling or other types of failures in cutting edge. 4.4. Collapse of soil beyond cutting edge: If the soil does not have adequate free-standing capability, the soil may fall down, especially during vibrations from passing trains. ‘Sometimes, this automatic collapse can go even beyond the cutting edge, causing hollow area which is not supported by either the Box or the cutting edge. This can lead to settlements in track and other related problems. Water filled up due to rains, during Box pushing operation.4.5. Movement of soil above the BOX during pushing operations: If the earth cushion is not adequate, soil above the Box starts moving with the Box during the pushing operation. This can lead to distortion of track alignment also. Track misaligned during BOX pushing 4.8. Obstructions stopping the pushing operations: Isolated large stones or rock outcrops in the path of Box pushing may increase resistance so much that the pushing work may have to be suspended till the stone or rock outcrop is removed. This might require the soill track to be supported to create space for the stone/ rock to be broken. Hard Rock encountered during Box pushing4.7. Filling up of water in BOX due to seasonal rains andlor high water table: If the water table is too high or there are rains during the BOX pushing operations, water may submerge the thrust bed and Part of the BOX rendering the BOX pushing work non- feasible. The efforts to lower the water table by heavy pumping can lead to reduction of shear capacity of soil and consequently its collapse.