Box Pushing Technique at Fathenagar RUB
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NArendra REddyBox Pushing Technique at Fathenagar RUB
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NArendra REddy- Introduction
- Box Pushing Technique Synopsis
- Box Pushing Operation
- Additional Safety Measures and Problems Encountered
- Acknowledgements
- Conclusion
Common questions
Powered by AIThe project team implemented several safety measures, including the allocation of a watchman to ensure train safety, maintaining a P.way gang with an experienced supervisor on track duty, and keeping materials like filled ballast, sand, and moorum bags ready for immediate use. They also constantly checked and corrected the alignment and level of the box and ensured proper bottom level excavation. Hydraulic jacking operations were paused during train passages, and drag sheet arrangements were strengthened. To address potential disturbances in track alignment, turfers and jacks were used to apply opposing forces for realignment .
Halting jacking operations during train passages was a critical safety decision. It minimized the risk of track disturbances or misalignments that could occur due to vibrations or other inadvertent forces during active jacking. This pause ensured that track integrity was maintained, preventing potential accidents. Although it might have slowed the project's pace, the decision prioritized safety, which is crucial given the proximity to active railway lines carrying both passenger and freight traffic .
Reference line pillars and TBMs were critical for ensuring precise alignment control. They provided fixed points and benchmarks against which the position and alignment of the box segments could be continuously checked. This ensured that as each segment was pushed, it remained on the correct path and level, preventing misalignment issues that could compromise the structural integrity of the underpass and the stability of the overlying railway tracks .
Strategic planning included advance analysis of site conditions, identification of likely challenges such as soil conditions and potential overburden collapses, and detailed scheduling to minimize train service disruptions. Safety protocols involved reinforcing rail support, ensuring track alignment, and maintaining equipment readiness such as hydraulic jacks and drag sheet greasing. Use of second cutting edges and cross rails to mitigate risk and maintain structural integrity during emergencies were also critical strategic components .
Hydraulic jacks were crucial for providing the force needed to push the large concrete box segments through the pre-constructed thrust bed. They offered precision control, ensuring that each segment was pushed without misalignment. Drag sheets, enhanced with greasing, reduced friction between the box and the thrust bed, enabling smoother movements without excessive force. The strategic placement and use of drag sheets helped in mitigating wear and ensuring consistent pushing progress .
Constraints included the lack of ready approach roads, requiring alternative methods for earth transportation. The construction site was in a heavily built-up city area, necessitating transportation during the night. Space limitations affected material storage and work area availability. Additionally, the presence of hard granite rock at the box's bottom slowed the pushing rate. These constraints required careful logistics planning and night operations to minimize disruptions and ensure continuous project progress despite these challenges .
The box pushing method used for the Road Under Bridge construction involved two large rectangular vents, each with inside dimensions of 11.0 m x 4.89 m. The construction utilized M35 concrete for the boxes, which were designed to accommodate 2-lane traffic. The earth cushion above varied between the up and down lines due to different track levels. Each vent segment was pushed using hydraulic jacks, and thrust beds were constructed from M25 concrete with pin pockets for jacking arrangements .
The thrust bed played a crucial role in facilitating the box pushing operation. It was constructed from M25 concrete and designed with pin pockets of specified dimensions reinforced with 6mm M.S. plate to distribute the jacking loads evenly. The careful design ensured the stability and durability needed to handle the forces exerted during the jacking process. Furthermore, the layered arrangement with drag sheets and a grease layer reduced friction, contributing to a smoother pushing operation without damaging the structure or surrounding infrastructure .
The design and material choices significantly impacted frictional resistance. Using M35 concrete for the boxes ensured structural integrity against compressive forces. The application of epoxy paint on box tops, along with dual layers of greased plastic sheets under the thrust bed, minimized friction. This combination of high-strength materials and surface treatments allowed the boxes to move more efficiently with less resistance, while maintaining structural safety under the track load .
The challenges encountered included the collapse of overburden ahead of the cutting edge, which was caused by the presence of sand pockets under the track. This resulted in a cavity that grew in size, threatening the stability of the track. To address this, additional rails and ISMB’s were inserted to support the running track, and moorum and sand bags were used over the intermediate and top cutting edges. Furthermore, the use of a second cutting edge and cross rails was implemented to provide immediate load transfer in case of local sinking under the sleepers. Measures such as greasing drag sheets and applying force with turfers and jacks helped maintain track alignment .
