BOX PUSHING TECHNIQUE: PROBLEMS AND REMEDIAL MEASURES

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Under auspicious guidance of Shri. S.K.Garg SPW/IRICEN/Pune Special thanks to Shri. V.B.Sood PB/IRICEN/Pune ByB.Tripathi K.K.Choudhary V.K.Khare ( C.N.- 9101 Integreted )

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Alternatives of constructing opening in railway track
• BY CONVENTIONAL METHOD (By providing Service Spans/R.H. Girders) • BY PUSH THROUGH METHOD

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Advantages of Box push through technique
• • • • • • No disruption to rail traffic. Better quality control. Economical Time of completion is less. Saving in man power & Machinery. No involvement of crane & heavy equipment. • Less involvement of other Departments.
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Disadvantages of Box Pushing method
1. Needs trained staff and skilled supervision. 2. Imposition of caution order exist for a longer period . 3. No scope of night working. 4. Once the vertical & lateral alignment of box disturbed it becomes almost impossible to rectify it.
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Collection of site data
• 1. Topography of area. • 2. Detail cross section considering • Rail level • Formation level • Width of embankment • Ground level • 3. Route of signaling cables, electric & telecom cables. • 4. Nearest river or Nallah course. • 5. Trail pit bore details. • On embankment • On ground level
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6. 5. Arrangement of adequate capacity jacks with power pack. 3. Construction of Wing wall/Toe wall/Return wall. Casting of box segments. 7 •Arrangement of jacks 8 4 .Stages in execution of work 1. Pushing operation. Excavation for thrust bed and auxiliary bed. Protection of track & embankment. 4. Concreting of thrust bed & pin pockets. 7. 2.

Shifting of longitudinal alignment. 6. – Creation of gap between two segments. Failure of pin pocket. 4. 9 Disturbance in track geometry. 5. – Reduction in space for ballast wall construction. Occurrence of collapsible strata. 9. Unexpected floods during box pushing. 7.Some problems encountered during box pushing 1. Occurrence of hard rock. Leaking of joints. 2. Tilting of box . – Differential earth cushion above box. • Effects – Lifting of track adversely. 3. 10 Tilting of Box 5 . – Excessive resistance in pushing subsequent segment. 8. Occurrence of boulder layer.

– Fix the reference points to check the vertical and lateral alignment regularly.• Remedies – Proper fixing of metal sheet at rear end of segments. – Preferably pushing should be 300mm at a time. – Differential jacking to rectify tilt. – Obstruction against cutting edge to be removed during pushing. 11 Tilting of Box Method to check the settlement of formation Plan Isometric view 12 6 .

Measure to control the lowering & lifting Plan Elevation 13 • Habibganj-Bhopal @ Km. 833/5-6 • Tilted box 14 7 .

• Habibganj-Bhopal @ Km. – Road becomes skew may lead to damages through hitting of box by vehicles . • Effects – Pressure on jacks of one side will increases abruptly may cause failure of jacks. 833/5-6 • Tilted box 15 Shifting of longitudinal alignment. 16 8 . – There will be a gap creation at the junction of two boxes.

– Regular checking the longitudinal alignment. – Differential jacking to rectify longitudinal alignment. 17 Checking the longitudinal alignment Plan Isometric view 18 9 . • Remedial Measures – Reference pegs to be fixed with respect to the centre line of box.Shifting of longitudinal alignment.

Failure of pin pockets 19 Precautions • Entire concrete to be casted in one go. • Concrete shall be dense & properly compacted. sheet of adequate thickness to be provided in pockets 20 10 . • M.S.

• Epoxy grouting to be done from inside. plate 22 11 . plate to be provided at top of the junction of two boxes . M.S.Leakage from joints 21 Precautions • M.S.

24 12 . – Disturbance in track geometry. – Ballast get through voids between boulders and drop down results hanging position of sleepers in unsafe condition. – Excessive pressure affects efficiency of jacks. – Hindrance in pushing hence more time consumption.M. plate 23 Occurrence of boulder layer • Effects – Obstruction to cutting edge.S.

– Preferably pushing carried out under traffic block.Occurrence of boulder layer • Remedial measures – Excess ballast unloading at site.720 26 13 . – Stablizing of sub grade by using Betonite power. 25 • BINA – KATNI Section @ Km. – Removal of boulders manually to be tackled in small segments of entire width. – Boulder removed segments to beprotected by providing gunny bags filled with sand simultaneously. 1020.

720 27 • BINA – KATNI Section @ Km. 1020.720 28 14 .• BINA – KATNI Section @ Km. 1020.

720 30 15 .• BINA – KATNI Section @ Km. 1020.720 29 • BINA – KATNI Section @ Km. 1020.

32 16 .• BINA – KATNI Section @ Km. – Slow process affects the entire progress. Manual excavation becomes ineffective. Bending of cutting edge.720 31 Occurrence of Hard rock • Effects – – – – Tilting of box / deviation in alignment. 1020. Failure of jacks due to excessive pressure.

Occurrence of Hard rock • Remedial measures – Mechanical arrangement like compressors. pavement breaker . 33 Pachora – Jalgaon section @ 383/22-24 34 17 . is required. – Controlled blasting may be resorted to. – Cutting edge should be designed as per site conditions. splitters etc.

– Arrangement of CC cribs and girders at site to deal emergencies. – Settlement of the track. – Small length to be attempted during pushing. – In case of collapsed bank RH girders to be provided .Occurrence of collapsible strata • Effects – Sudden collapse of sub grade. – Frequent recoupment of Ballast & track attention. 36 18 . – Safety hazards during passage of traffic. – Sufficient numbers of gunny bags filled with sand kept ready. 35 Occurrence of collapsible strata • Remedial measures – Stabilization of sub grade with Betonite. – Cautious & slow process.

• JALGAON – BHUSAWAL @ Km. 428/8-10 38 19 . 428/8-10 37 • JALGAON – BHUSAWAL @ Km.

• JALGAON – BHUSAWAL @ Km. 428/8-10 39 • JALGAON – BHUSAWAL @ Km. 428/8-10 40 20 .

– Revision of caution orders as per site conditions. 42 21 . – Disturbance to cess require protections. – Submergence of machinery interrupt the process. – Sufficient numbers of gunny bags filled with sand kept ready. – Shoring arrangements to be made available. – Collapse of bank due to water current & heavy rain. – Excessive friction due to wet soil mass. 41 Unexpected flood during box pushing • Remedial measures – Unloading of Boulder / quarry dust rake for bank protection.Unexpected flood during box pushing • Effects – Damage to the slope of the banks. – Water pumping arrangements along with provision of coffer dams.

1020.Unexpected flood • BINA – KATNI Section @ Km.720 44 22 . 1020.720 43 Disturbance due to unexpected flood • BINA – KATNI Section @ Km.

Disturbance due to unexpected flood • BINA – KATNI Section @ Km. 1020.720 45 Disturbance due to unexpected flood • BINA – KATNI Section @ Km.720 46 23 . 1020.

1020. 1020.Disturbance due to unexpected flood • BINA – KATNI Section @ Km.720 48 24 .720 47 Disturbance due to unexpected flood • BINA – KATNI Section @ Km.

1020.Disturbance due to unexpected flood • BINA – KATNI Section @ Km.720 50 25 . 1020.720 49 Disturbance due to unexpected flood • BINA – KATNI Section @ Km.

1020. 1020.Disturbance due to unexpected flood • BINA – KATNI Section @ Km.720 51 Shoring arrangements • BINA – KATNI Section @ Km.720 52 26 .

1020.720 54 27 .720 53 Shoring arrangements • BINA – KATNI Section @ Km. 1020.Shoring arrangements • BINA – KATNI Section @ Km.

1020.720 56 28 .Shoring arrangements • BINA – KATNI Section @ Km. 1020.720 55 Shoring arrangements • BINA – KATNI Section @ Km.

Disturbance of track geometry • Effects – Abrupt cross level variation. – Lateral shifting of the alignment. – Resulting in deficiency of ballast requires frequent recoupment. – Bulging of side slopes.720 58 29 . – Shifting of earth mass along with box. 57 • BINA – KATNI Section @ Km. 1020.

– Daily pushing without interruption to avoid frictional resistance . – Unloading of sufficient ballast well in advance. 59 • Epoxy painting 60 30 .Disturbance of track geometry • Remedial measures – Arrangement of Tirfors to resist the movement of track along with box. – Epoxy painting on top surface/use of drag sheet to reduce friction. – Deployment of sufficient labour to correct the disturbed track structure. – Counter weight on the exit end of bank. – Recording of track parameters & frequent attentions.

• Drag sheet arrangement for smooth pushing 61 • Drag sheet arrangement for smooth pushing 62 31 .

• Drag sheet arrangement for smooth pushing 63 • Counter weight 64 32 .

misalignment etc. • LWR must be cut and site isolated during box pushing.Conclusions and Suggestions • Box pushing work means at least partly working in blind . settlement. 65 66 33 . so problems usually come up during execution of work. • Box pushing work require close supervision and monitoring and quite often the unsafe conditions develop at these sites. • Work must be done under block protection / caution order only. • Track must be watched regularly to see signs of heaving.

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