Box Jacking Technology for

Fast Track Underpass

Construction

Dr. Manamohan R Kalgal

Vice President – Technical Services
GRASIM INDUSTRIES LTD.
 TUNNELING by BOX JACKING

Non-intrusive method
Non-

Traffic flows to be maintained throughout
the construction period

Development of high capacity jacking
equipment and sophisticated techniques
for controlling ground disturbance

Jacking of very large boxes each capable
of accommodating a highway, railway or
flood defense channel.
 Typical Procedure
Open-ended reinforced concrete box
cast on a jacking base adjacent to the
road
A purpose designed tunneling shield is
provided sometimes at its leading end
Thrust jacks are provided at its rear end
reacting against a jacking beam/thrust
bed
The box is then jacked slowly through
the ground under the road/railway in a
carefully controlled tunneling operation.
Excavation and jacking take place
alternately in small increments of
advance
Measures are taken to ensure stability
of the tunnel face and to prevent the
ground from being dragged forward by
the advancing box
 When the box has reached its final
position, jacking equipments are
removed, and
Auxiliary works and approach road
pavement are constructed
Anti Drag System

Several large box structures installed in a
wide variety of ground conditions

In India, this technique has been explored
by Indian Railways extensively

However, only a few underpasses
constructed below highways using this
technique
 Case - Study

Location

Need for Underpass

Need for Trenchless Technology

Role of IISc

Role of BBR
 General
Arrangement
Longitudinal Section
 The Challenge
To finish the entire project
including access roads and
appurtenances in 148 days
 Strategies Adopted

Near perfect and optimised schedule
worked out

Identifying of right sub-
sub-agencies

Mechanised Tunnel formwork
High--strength RMC (28 N/mm2 in 48 hrs.)

High

Adoption of Soil Nailing Technique

Constant Monitoring and updating of
schedules as and when necessary
Intitation of Work
Excavation for Approach Ramp
Soil Nailing for Retaining Soil
Pit for Casting the Element
Reinforcement for Pushing Raft
Concreting of Raft
Shutter for Bottom 1/3 Casting
Shutters of Bottom 1/3 Portion of Element
Shutter for Top 2/3 Casting
Top Shutter Component being Lowered
Top Shutter Components Assembled and
Rebar Work in Progress
Reinforcement
Details
Element ready for Casting
Fully Cast First
Element
Getting ready to cast Bttom 1/3 of 2nd Element
Bottom 1/3 of Second Element being cast
Fixing of Drag Sheet
Jacks in place for Pushing
Pushing in Progress
Light at the end of Tunnel!
Concreting of Approach Ramps
The completed Underpass
The completed Underpass
The completed Underpass - inside view
The completed Underpass - inside view

Drainage / Rain water harvesting
system

Quality Control

Safety and Environmental Concerns
 CONCLUDING REMARKS

The experience of executing this type of prestigious and
technologically innovative project has revealed that
– the ‘Box-
‘Box-Jacking’ Technology is the most suitable one for
the construction of under-
under-passes across busy highways/
expressways.
– This fast-
fast-track trench-
trench-less technology may be exploited
advantageously, not only to construct underpasses for
pedestrian and vehicular traffic, but also to provide
facilities such as metro rails and service vents across
highways and expressways.
– This technology provides a distinctive advantage over
‘cut--and
‘cut and--cover’ method in such situations, due to its
execution without interruption of traffic above with the
constraints of tight time schedule.