Fig - 1 Road Under Bridge
Fig - 1 Road Under Bridge
CHAPTER 1
INTRODUCTION
The Box Pushing Method (BPM) is an innovative and efficient technique used in the
construction of road under bridges, revolutionizing the way infrastructure projects are
executed. This method involves the installation of pre-fabricated boxes or segments
beneath existing structures, such as highways or railways, to create an underpass for roads
or utilities. In this process, a series of pre-constructed reinforced concrete or steel boxes
are carefully maneuvered into position beneath the existing bridge or structure. These
boxes serve as the foundational elements for the road underpass. The key advantage of
this method is its minimal disruption to traffic and nearby communities during
construction, as it significantly reduces the need for extensive excavations and traditional
construction techniques. Box pushing offers several benefits, including reduced
construction time, cost-effectiveness, and enhanced safety. By avoiding prolonged road
closures and detours, it minimizes inconveniences to commuters and businesses.
Additionally, it is an environmentally friendly approach, as it reduces the environmental
impact associated with conventional construction methods. The box pushing method is a
cutting-edge solution for constructing road under bridges, prioritizing efficiency, safety,
and sustainability. Its ability to create underpasses while minimizing disruptions makes it
an attractive choice for modern infrastructure projects.
CHAPTER 2
2.1 NECESSITY FOR CONSTRUCTION OF ROAD UNDER BRIDGE
The necessity of the box pushing method in road under bridges can be understood by
considering several key factors:
Safety is a top priority in construction projects, and the box pushing method reduces the
risks associated with open excavation sites. By minimizing the exposure of construction
workers to live traffic and reducing the need for road closures, the method inherently
enhances safety conditions on the construction site.
The reduced excavation and construction time associated with box pushing lead to a
smaller environmental footprint. This method minimizes soil disturbance, potential
groundwater contamination, and disruption to local ecosystems, making it a more
sustainable option for road under bridge projects.
2.1.4 Cost-Effectiveness
In urban areas or locations with limited space for construction activities, box pushing
offers a practical solution. It allows for the construction of road under bridges without
encroaching on adjacent properties or requiring extensive land acquisition.
Box pushing allows for the preservation of existing infrastructure, such as the road or
railway above the bridge, by minimizing the need for extensive demolition and
reconstruction. This can extend the lifespan of the existing structure and reduce long-term
maintenance costs.
The box pushing method is known for its efficiency, allowing for faster project
completion compared to traditional construction methods. This is particularly important
when addressing urgent transportation needs or time-sensitive infrastructure
improvements.
Road under bridges, often referred to as underpasses, are essential components of modern
transportation infrastructure. These structures are designed to allow roads to pass beneath
existing bridges, highways, or railways, providing uninterrupted vehicular and pedestrian
movement. They play a pivotal role in enhancing traffic flow, reducing congestion, and
improving safety on road networks. One of the primary purposes of road under bridges is
to eliminate level crossings, where roads intersect with railways. These crossings pose
significant risks to both road and rail users, and underpasses mitigate these risks by
separating the two modes of transportation. By doing so, they contribute to a reduction in
accidents and fatalities, making travel safer for all.
Furthermore, road under bridges are crucial in urban and suburban settings
where land is often at a premium. Traditional methods of constructing elevated roadways
or railway lines can be expensive and environmentally disruptive. In contrast, underpasses
make efficient use of available space by allowing roads to pass beneath existing
structures. This minimizes the need for extensive land acquisition and costly demolitions
while preserving the integrity of the overlying bridge or highway. The construction of
road under bridges is not only about improving safety and optimizing space but also about
enhancing the overall efficiency of transportation networks. They reduce traffic
congestion and bottlenecks, facilitating smoother traffic flow. This, in turn, results in
reduced travel times, lower fuel consumption, and decreased air pollution. Moreover,
underpasses improve accessibility, connecting communities and promoting economic
development by making it easier for people and goods to move within regions.
Moreover, a 50mm screed is applied over the thrust bed to achieve the exact line and
level necessary for the pushing operation's success. In addition to the above elements,
precast cover blocks are strategically placed at the locations of the pin pockets. These
cover blocks serve a dual purpose: they protect and secure the jacking pins within their
respective pockets, preventing any inadvertent movement or damage during the jacking
process, and they ensure the overall integrity of the thrust bed system. Thus, the thrust
bed, with its thrust wall, pin pockets, leveling screed, and cover blocks, plays an
indispensable role in providing the essential resistance required for efficient and precise
jacking operations during bridge construction.
It is a MS Plate which is made up of mild steel material and used in the site for cutting
the soil surface under the railway track. It has cutting edges in the front which helps to
cut the soil and move the box segment easily.
It is made up of mild steel will be fixed on rear end of the first unit of the box. This is
connected to the back side of the RCC box segment which helps the box to move
properly with out and tilting under the railway track.
The above process of pushing first segment after excavating and removal of
soil and pushing of second segment to close the gap created in IJS as described above
will be continued taking care that a minimum overlap of about 200mm is always
available to the top of front portion of second segment as the rear shield is preventing the
soil above and onside of the box. During the process of jacking both units one after the
other alignment of the box and level will be checked immediately before and after each
pushing operation and in case of misalignment it will be corrected by adjusting the
operation of different hydraulic jacks.
2.3.7 PISTON
The cylindrical machine in question is a vital component in the construction of road under
bridges, specifically designed for the task of pushing the constructed box into its
designated position. This innovative machinery is engineered to exert a substantial
amount of pressure, typically ranging from 400kN to 600kN, to facilitate the smooth and
precise movement of the massive box structure. This force is applied strategically to
propel the box through the embankment, ensuring it aligns accurately with the intended
location. The machine's cylindrical design allows for efficient and controlled movement,
minimizing disruptions to traffic and optimizing the overall construction process.
2.3.8 POCKETS
In the context of the box pushing method, pockets play a crucial role in construction
site operations. These pockets are essentially holes created at the construction site, and
they serve multiple purposes throughout the project. Initially, before covering them up
with concrete, these pockets are filled with red sand to a height of approximately 70cm.
One primary function of these red sand-filled pockets is to act as markers at the
construction site, helping in the alignment and positioning of various elements during
the RCC work.
Once the RCC work is completed, the red sand is removed from these pockets, and they
are then utilized for a different purpose. These emptied pockets serve as locations where
the counter box, a critical component in the box pushing method, is securely placed. This
strategic use of pockets facilitates the precise and controlled movement of the constructed
box into its intended position within the road under bridge, ensuring accurate alignment
and a successful construction process.
Positioned within specially prepared pockets at the construction site, the counter box
serves as a stable anchor point for the hydraulic piston. Its substantial weight and robust
construction ensure that it can withstand the substantial forces involved in pushing a
massive box structure through the embankment. By securely placing the counter box in
these pockets, the entire system becomes balanced and capable of executing the pushing
operation with precision and safety. This strategic use of the counter box is essential for
maintaining the structural integrity and successful installation of road under bridges
through the box pushing method.
2.3.10 BISCATE
In the context of the box pushing method, "biscates" play a vital role in the process.
These specialized components are strategically positioned in front of the piston, and
they serve as essential aids in pushing the constructed box into its designated position
within the road under bridge. Biscates are designed to facilitate the smooth and
controlled movement of the massive box structure. By acting as a buffer or interface
between the piston and the box, they help distribute the force evenly, minimizing any
potential damage or uneven pressure during the pushing operation. The use of biscates
is crucial to ensure the structural integrity and precision of the box pushing process.
Their careful placement and design contribute to the successful installation of road
under bridges, allowing for accurate alignment and efficient construction while
minimizing the risk of structural damage.
Collecting data for the box pushing method in road under bridges is a critical aspect of
project planning and execution. This data collection process involves gathering
information related to various aspects of the construction method to ensure its successful
implementation.
surrounding community. This data collection is fundamental for ensuring the well-being
of all involved in the project.
2.4.2 Excavation
The initial step in constructing a road under bridge involves excavating the
site to a predetermined depth below ground level. This excavation is crucial to ensure that
the box structure provides sufficient clearance for vehicles to pass through comfortably
while adhering to a road gradient of 1 in 40. Typically, this excavation process can be
carried out manually or with the assistance of mechanical equipment, such as hydraulic
excavators. However, challenges arise when the site contains hard rock strata. In such
cases, traditional excavation methods may prove impractical. When confronted with hard
rock formations, the excavation process often requires the use of more specialized
techniques, such as blasting or chiseling. While blasting is an efficient way to break
through hard rock, it may not be suitable for all locations, particularly in densely
populated areas where safety concerns are paramount. Chiseling, though a somewhat
more costly and time-consuming approach, becomes the method of choice when blasting
is neither feasible nor safe due to the proximity of inhabited areas. This meticulous
process involves the gradual removal of rock layers, ensuring that safety and structural
integrity are maintained throughout the excavation. In essence, the choice between
excavation methods depends on the specific geological conditions and the project's
location, with safety considerations always at the forefront of decision-making.
The laying of the thrust bed constitutes a crucial phase within the box pushing
technique for constructing road under bridges. This phase assumes significant importance
as it plays a pivotal role in managing the reaction force generated by the hydraulic jacks
during the box pushing process. The thrust bed effectively counters this force and
channels it into the surrounding soil, making it an indispensable element in facilitating
the smooth advancement of the box into the embankment. To accommodate the necessary
jacking support, specialized pockets are incorporated into the thrust bed's design. These
pockets are strategically positioned to house the pin supports that interface with the
hydraulic jacks. Once the jacking operation is completed, the thrust bed transitions into a
functional floor bed, serving as a stable foundation for the subsequent stages of the
project. It remains in place, providing essential support throughout the construction
process, ensuring the structural integrity and stability of the road under bridge project.
The box pushing method for constructing road under bridges involves a systematic series
of steps that ensure the successful installation of the bridge structure. It all begins with
the essential reliance on the thrust bed reaction, where the initial screed-equipped thrust
bed is meticulously dismantled within the pin pockets. These pockets are then thoroughly
cleaned and prepared to accommodate the installation of pins in their designated
positions. Hydraulic jacks play a pivotal role in the process, positioned between the pins
and the bottom slab of the leading box segment. The inclusion of spacers and packing
plates helps maintain precision and stability during this critical phase. To safeguard the
concrete structure from severe damage, a 20mm thick plate is thoughtfully placed and
secured against the slab's bottom. Furthermore, measures are taken to prevent the earth
from caving in during the operation, with 25mm HYSD rods, spanning 12 meters in
length and spaced at 500mm intervals, strategically inserted into the soil. Every 200mm
push necessitates the release and subsequent repacking of the hydraulic jacks with spacers
and packing plates.
As the process advances, the second box segment is carefully positioned behind the first,
and hydraulic jacks, each with a capacity of 300 tons, are mounted between these
segments. An additional set of 300-ton hydraulic jacks are thoughtfully placed between
the thrust bed and the second segment. These hydraulic jacks, distributed in two slots on
either side of the wall, serve to monitor the alignment and level of the box segment during
the pushing process. Earth remnants in front of the first segment are methodically carved
away during pushing, and nails are introduced to reinforce the embankment. The
procedure repeats for each subsequent box segment until the first box segment is securely
in place. Any segments that deviate from the desired alignment are carefully brought back
into line with the box pushing operation.
Finally, the corners of the boxes are filled with concrete, ensuring
structural stability and completing the construction process. This systematic approach
guarantees the successful placement of each box segment in the road under bridge,
contributing to the creation of a robust and reliable infrastructure.
Upon the completion of the box pushing method for constructing the road under bridge,
the foundation of the road is prepared for its intended purpose – facilitating traffic flow.
The innovative construction technique ensures that the road is structurally sound and
ready to serve its vital role. The road's foundation can be composed of either bituminous
or concrete materials, depending on project specifications and engineering
considerations. Bituminous roads provide flexibility and are known for their smooth
surface, making them suitable for various traffic loads and conditions. On the other hand,
concrete roads are recognized for their strength and durability, often preferred for heavy
traffic routes.
2.5 ADVANTAGES
The box pushing method for constructing road under bridges offers a
multitude of advantages that make it a preferred choice for infrastructure projects. One of
its most significant benefits is its minimal disruption to rail traffic. Unlike traditional
construction methods that often require significant rail closures and detours, the box
pushing technique allows for the construction of road under bridges without causing
disruptions to ongoing rail operations. This minimizes inconveniences to both commuters
and the railway sector. Moreover, the method provides better quality control as the precast
box segments can be fabricated under controlled conditions, ensuring uniformity and
structural integrity. This contributes to the overall durability and reliability of the bridge
structure.
Economical considerations also come into play, as the box pushing method
is cost-effective. It reduces labor and material costs, and its efficiency results in overall
project savings. Additionally, the method accelerates project timelines, leading to faster
completions, which is advantageous in addressing urgent transportation needs. The box
pushing technique is also notable for its resource efficiency. It requires less manpower
and machinery compared to conventional methods and does not involve the use of cranes
or heavy equipment, making it a more environmentally friendly option. This minimizes
noise, emissions, and disturbances to nearby communities. Furthermore, the method
involves less coordination with various departments and agencies, simplifying the
permitting and approval process. This streamlined approach ensures smoother project
execution and quicker delivery. The box pushing method's benefits, including minimal
rail disruption, superior quality control, cost-effectiveness, faster completion times,
resource efficiency, and reduced interdepartmental involvement, make it a highly
advantageous choice for road under bridge construction, aligning with the modern goals
of efficiency, sustainability, and convenience in infrastructure development.
2.6 DISADVANTAGES
Despite its many advantages, the box pushing method for road under bridge construction
does come with several notable disadvantages that warrant consideration. Firstly, it
demands a workforce comprising trained staff and skilled supervision due to its intricate
nature. The need for specialized knowledge and experience can increase project costs and
potential delays if qualified personnel are not readily available. Another drawback is the
potential imposition of caution orders for a prolonged period. This can impact nearby rail
or road traffic, causing disruptions and inconvenience, especially in cases where
meticulous planning and execution are required. Additionally, the method does not offer
the flexibility of night working, limiting construction hours to daytime schedules. This
constraint can extend project timelines and may not align with time-sensitive construction
needs.
Perhaps one of the most significant challenges is that once the vertical and lateral
alignment of the box is disturbed during the construction process, rectifying it becomes
an exceedingly complex and time-consuming task. This vulnerability underscores the
importance of precision and careful planning during the initial stages of the project.
Lastly, the box pushing method faces difficulty when confronted with hard rock strata. In
such geological conditions, traditional excavation methods like blasting or chiseling may
be required, increasing project complexity, time, and cost. While the box pushing method
offers numerous advantages, it is essential to recognize and address its associated
disadvantages, such as the need for specialized personnel, caution orders, limited working
hours, alignment challenges, and difficulties in hard rock strata. Effective project
planning and risk mitigation strategies are crucial to navigate these challenges and ensure
successful road under bridge construction.
CHAPTER 3
CONCLUSIONS
The box pushing method for constructing road under bridges is a proven and efficient
engineering technique that offers numerous advantages in terms of speed, cost-
effectiveness, and minimal disruption to traffic. Through this seminar, we have explored
the key features and benefits of this innovative construction approach. First and foremost,
the box pushing method significantly reduces construction time, as it eliminates the need
for traditional excavation and bridge building techniques. This time-saving feature not
only minimizes inconvenience to commuters but also reduces the overall project costs.
The method's minimal environmental impact and reduced noise pollution make it an
environmentally friendly option. It also ensures the safety of workers and commuters by
minimizing exposure to construction hazards and traffic disruptions. The box pushing
method's adaptability to various soil conditions and bridge spans makes it a versatile
choice for a wide range of projects. Its ability to accommodate various road widths and
traffic loads enhances its applicability to urban and rural settings alike. The box pushing
method is a groundbreaking construction technique that has revolutionized the way road
under bridges are built. Its speed, cost-effectiveness, safety, and environmental benefits
make it a compelling choice for infrastructure development projects in the 21st century.
As we continue to seek innovative solutions for our infrastructure needs, the box pushing
method stands out as a transformative approach that merits further exploration and
adoption in the construction industry.
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Phatak, Devendra J. Sawant, Jay P. Digaskar, Omkar C. Shinde, Yashraj B. Mahind
3. CONSTRUCTION OF ROAD UNDER BRIDGE USING BOX PUSHING
TECHNOLOGY Anushree M, Bharath R, Chandandev N, Navya Shree M C,
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