BOX PUSHING TECHNIQUE

ABSTRACT

Introduction of Box Pushing Technique:-

Present day Intensity of Traffic, both Rail & Road due to the fast development of Industries and
other Infrastructures, is very heavy and so it cannot the disturbed, for construction of under
bridges or Canal Crossings, drainage etc by conventional i.e. open cut system. So to construct
such structures, Box Pushing Technique is developed where in R.C.C. Boxes in segments are
cast out side and pushed through the heavy embankments of Rail or Road by Jacking. The
required thrust is generated through thrust bed, as well as line & level of precast boxes are also
controlled.

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 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 is on an embankment and space exists for the structure to be
cast at the side.

The main benefit of this approach is that it is non disruptive and non-intrusive. Tunnel jacking
can install the final structure in one go, it also allows the above infrastructure to remain “live”
and active during the work.

The entire system is purely technical, dependent on Hydraulic system, & safest method of
crossing underground / Embankment, without disturbing overhead traffic / structures for
R.U.B., Canal siphon and other drainage crossings.

HISTORY
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Tunnel jacking or jacked-box tunneling is a non-intrusive method of constructing railway or

subway tunnels, large oversized culverts, or an under-bridge by pushing a huge concrete box
through the soil using specialized jacking equipment and hydraulic jacks.[1] The obvious
benefit of the tunnel jacking method is that construction of shallow tunnels can resume under
existing infrastructure or structures above with minimal disturbance.

The concept of tunnel jacking originated from pipe jacking in the 1960s whereby small pre-cast
concrete boxes were jacked under existing infrastructures to form pedestrian subways, and
portal bridges, and in underground pipeline construction. Eventually, the technique was adapted
in the building of bridge abutments. Small boxes were jacked into place on top of each other
and then filled with concrete. The technique eventually evolved into jacking concrete tunnel
sections of monolithic proportions that were big enough to accommodate the construction of
three-lane highways running underneath railways, highways, rivers, and airports.

Certain items concerned with the method are explained below.

Thrust bed :

The Thrustbed and Thrust Beam and keys are designed in R.C.C. to resist the required Thrust
extorted by Jacking force and 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. On completion of Jacking
the thrust bed is utilised as floor bed, and so it is left in place.

Precast R.C.C. Box

The Precast Box is cast in segments of convenient lengths of Total pushing length. The Box
section is designed as per IRS / IRC codes of practice for loading. Concrete grade normally kept
as M-35.

Front Cutting Shield & Rear Jacking Shield

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The First Segment of the precast box is provided with a specially designed structure
named as cutting shield which forms the front working face with a cutting edge
fabricated from 16 to 20 mm thick M.S. Plates and housed on RCC Box section with
suitable anchor bolts. Necessary strengthening is provided by stiffeners and face plates of
Box in front on completion of jacking the outer shell of the shield is cut and removed

The Rear Jacking shield is provided by anchoring steel plate on the face of Bottom slab
of RCC Box suitably designed to distribute the jacking load uniformly on concrete area.

Intermediate Jacking Station

As total length of Box is cast in Segments, each segment is pushed turn by turn with
necessary jacking force and so for this necessary intermediate jacking stations are
provided, with jacking pockets in bed & walls.

Drag Sheet:

The arrangement reduces frictional

forces acting on box during pushing and thereby

minimizes jacking effort and track disturbances

otherwise encountered during box pushing.

Pushing Operation of the Box

The purpose of pushing of Box is to form a horizontal opening below ground or through
embankments, can say a tunnel, by providing precast box units underground or an
embankment, without disturbing the overhead amenities, like traffic & structures.
To reduce the frictional resistance, a thin film of Grease and thick gauge plastic sheet is
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 disturbance of the mass over box to least during progress of pushing

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 of mass above box.

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Auxiliary beds are also provided for casting of the other segments with thin film of grease and
plastic and 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
and there after excavation within the shield is done either manually or mechanically and
the excavated stuff is transported outside the working area.

After the first segment advances to the end of the thrustbed, the second segment is brought in
alignment of the front Box & intermediate jacking space is lift between the two. The progress of
pushing is kept continuous and the system of side shifting of remaining box segments from
Auxiliary bed and bring in pushing alignment is adopted till total length is pushed.

Hydraulic Equipment

The entire Box Pushing system is matter of proper selection of Hydraulic equipments, as
tremendous driving force is required for pushing of medium to large size of Boxes. So for this,
Number 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 of required pressure
capacity, commencing from front unit to rear unit. Jacking force is applied in sequence. This
way pushing cycles are repeated till total pushing is completed

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Basic Principles

Figure 1- illustrates the basic jacking sequence of jacked box tunneling under an existing
railway. The box structure is constructed on jacking base in a jacking pit located adjacent to one
side of an existing railway. A tunneling shield is provided at the front end of the box and
hydraulic jacks are provided at the rear. The box is advanced by excavating ground from within
the shield and jacking the box forward into the opening created at the tunnel heading. In similar
fashion to pipe jacking, lengths of tunnel that would exceed the capacities of jacks situated at
the rear of the box structure can be successfully advanced into place by dividing the box
structure into sections and establishing intermediate jacking stations. The box structure shown
in Figure 1- is divided into two sections with an intermediate jacking station set up in between
them.

In order to maintain support to the tunnel face, excavation and jacking normally carried out
alternately in small increments, typically in the range of 2 to 4 feet. In most cases, the soft
ground must be treated by means of ground improvement techniques such as ground freezing,
jet grouting, etc. Soft Ground Tunneling to enhance its stand up time.

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Figure 1:-Typical Jacked Box Tunneling Sequence under an Existing Rail Track

Applications

Some examples of potential box jacking projects include storm drains, bike or pedestrian trails,
livestock or wildlife undercrossings, conveyors, pipeways and other industrial uses, small
bridges, and roadways up to 4 lanes wide. Basically, applications of box jacking depend only on
the creativity of the civil engineer designing the project.

Most box jackings Berkeley Engineering has been involved with have been for drainage. The
paving incidental to increased urbanization causes larger instant runoff sand larger storm drains
are then required. Where these larger channels must pass beneath highways, railroads or the
like, tunneling will often be required. Up to 8’ or 10’ diameter, pipe jacking will often be
utilized. But larger sizes are generally rectangular. Placing these larger channels

Collection of site data

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• 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

PRE WORK FOR BOX PUSHING

• Since it was highly time bound project, Work Methodology, Sequencing of

activities & Schedule of Construction was finalized in consultation with

contractor.

• Trial trenching was done, in embankment and thrust bed location, to identify

buried utilities such as S&T and Electrical cables, water supply pipeline etc.

• All the cables, about 80 nos., and C.I. pipeline-300 dia were dug out, realigned

and protected prior to starting of box pushing work.

Stages in execution of work

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1. Excavation for thrust bed and auxiliary bed.

2. Concreting of thrust bed & pin pockets.

3. Casting of box segments.

4. Protection of track & embankment.

5. Arrangement of adequate capacity jacks with power pack.

6. Pushing operation.

7. Construction of Wing wall/Toe wall/Return wall.

Some problems encountered during box pushing

1. Tilting of box .

2. Shifting of longitudinal alignment.

3. Failure of pin pocket.

4. Leaking of joints.

5. Occurrence of boulder layer.

6. Occurrence of hard rock.

7. Occurrence of collapsible strata.

8. Unexpected floods during box pushing.

9. Disturbance in track geometry.

Following precautions are required to be taken:

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 Line and Level of the box is to be checked after every push. In case of deviation,
 corrective action scheme to be immediately formulated and implement during next
 push.
 Line and Level of the tracks is to be checked and restored after every push.
 Earth must not be excavated beyond the tip of cutting edge i.e. tip of cutting edge must
always remain buried in earth.
 Boxes are to be pushed when there is no train on any of the tracks. Pushing needs to
restricted to day hours.
 Surface erosion of sandy strata must be prevented. Proper records should be
 maintained to ensure correct driving of soil nails.
 At least 3 nos. Walkie -Talkie sets to be provided at site for effective
 communication between Power Pack Operator, SE/Works and SE/P.way.

Box Pushing Operation

 To push precast box segment, reaction is obtained from thrust bed. For this, screed is
dismantled at pin pocket location, pin pockets are cleaned, pins are inserted and
Hydraulic Jacks- 8/10 nos. are installed between pins and bottom slab of the box with
packing plates and spacers.
 A 20mm thick plate is provided , butting against bottom slab of box, in front of the jacks
to avoid damage to concrete surface.
 Nail anchor plates are removed and earth is manually excavated in front of cutting edge
in a way to get annular clear space of 300mm all-round.
 Anchor plates are refixed in position and uniform pressure is applied to the jacks through
Power Pack
 After complete push (maximum 300mm) jacks are released, protruding nails are
gasbcut/driven and jacks again packed with packing plates and spacers.
 Process is repeated till front box is pushed to required position.
 Then 2nd box segment is slewed and brought in position behind 1st box segment.
 8 nos. Jacks ,each of 200 Tons capacity, are housed between two box segments in
addition to 8 nos. Jacks already provided between thrust bed and 2nd box segment.
 3 nos. Jacks ,each of 100 Tons capacity, are provided in 3 slots made in each side walls to
facilitate correction of line and level of box during pushing.

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 Earthwork is now done in front of 1st box segment and it is pushed. Protruding nails are
gas cut/driven and anchor plates are refixed in position.
 Thereafter, jacks housed between two box segments are released and then 2nd box
segment is pushed.
 Process is repeated till both the box segments are pushed to required position.
 Cutting Edge is dismantled & front face of 1st box segment is cast in plumb.

Schematic diagram for box being jacked beneath railway

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Fabrication of Front Shield

It is fabricated for cutting action and to provide support , to prevent caving in of soil.

Fabrication of Rear Shield

It is provided by anchoring steel plates on the face of bottom slab of RCC box to suitably
distribute the jacking load.

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Construction of Thrust Bed in progress

Construction of Box Segments

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Jacking Arrangement

End Support Frame for provision of Drag Sheets

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Applying grease to launch slab

General arrangements made for provision of Drag Sheets

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Cutting Edge with arrangement for provision of Drag Sheets

Insertion of steel built up relieving girders @ 1.20 m c/c for protection of track during
pushing operation

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Shield entering ground

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.

Disadvantages of Box Pushing method

 Needs trained staff and skilled supervision.

 Imposition of caution order exist for a longer period.
 No scope of night working.
 Once the vertical & lateral alignment of box disturbed it becomes almost impossible to
rectify it.

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