Summer Training Report

On
CONTRUCTION OF AN UNDERBRIDGE PROJECT AT
PHAPHADIH
(28thmay 2018 – 30thJune 2018)
Submitted by
ANKIT PANWAR (15114011)
NIT Raipur

Under The Guidance Of

Mr. Sabir Khan (Sub-Engineer)
Mr. Pankaj Chandrakar (Sub-Engineer)
Mr. C.K.Pandey (Sub-Divisional Officer)
Public Works Department, RAIPUR
 Acknowledgement

We are grateful to Mr. Sabbir Khan Sir for accepting and allowing
us to do training. His instructive suggestion and careful guidance
have helped us to learn. His continuous support and motivation has
helped us to face difficulties during the training.

We specially thank to Mr. Sabbir Khan Sir for giving us the

opportunity to work in such a reputed Organization (PWD).We learn
many new things regarding Under Bridge Construction.

We would like to thank Mr. Sabbir Khan Sir for giving us the
guidance and care during our training. We enjoyed every bit of
training and refreshing moments on the site because of them.

ANKIT PANWAR
NIT RAIPUR
Table of Contents
Abstract
1. INTRODUCTION
1.1. Necessity for Construction of Road Under Bridge
1.2. Planning sequence for under bridge construction
1.3. Steps to construct an underpass

2. SPECIFICATIONS AND PROCEDURES

2.1. Specification of a single box
2.2. Procedure of box pushing
2.3. Casting of RCC box segments
2.4. Pushing of box segments
3. COMPONENETS OF CONTRUCTIONS
3.1. Thrust Bed
3.2. U-Type Retaining Wall
3.3. Front Shield
3.4. Rear Shield
3.5. Drag Sheets / Epoxy Coating
3.6. Drainage of Under pass
3.7. Pavement
4. ADVANTAGES OF BOX PUSHING

5. DISADVANTAGES OF BOX PUSHING

6. PROBLEMS ENCOUNTERED DURING BOX PUSHING

7. SELECTION OF SITE DATA

8. CONCLUSION
ABSTRACT
Under Bridges are required to be provided under earth embankment for crossing of
Vehicular/Road traffic, railway traffic across the level crossing of Railway line, etc. The
under Bridges are also required in urban area where the busy Business location streets
crossing to Railway lines etc. 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 be disturbed, for construction of under bridges or drainage etc by conventional i.e.
open cut system. So to construct under bridges without disturbing the existing Railway /
Road embankment we have chosen to construct the RCC BOX CELL BRIDGE by Box
Pushing Technique, where in R.C.C. Boxes in segments are cast outside 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.
The box segments design and Analysis part is very simple and not critical. To push the
Box into the embankment of railway is also not a major problem, the required thrust can
be generated from thrust bed by jacking. After completion of the work Thrust Bed can be
used as a protection work in Hydraulic structures and rigid pavement work in Highway
structures. The required bearing capacity of soil is very little. Safest method of crossing
underground / Embankment, without disturbing overhead traffic / structures for R.U.B
(Railway under bridge).
1. INTRODUCTION

An underpass, or subway, is a tunnel containing a road or pedestrian passageway running underneath

a road or railway. Underpasses can also be constructed to allow wildlife to pass safely under
a transport corridor.

There are three main methods for constructing underpasses:

✓ Precast concrete units.

✓ In situ concrete.
✓ Thrust-bored units.

1.1. Necessity for Construction of Road Under Bridge

With the continuous increase in the rail traffic as well as road traffic, the interface between rail and road
traffic is bound to multiply as we proceed towards becoming a developed nation. Grade separators i.e.
Road over bridges / Road under bridges / subways, therefore, shall not only ensure the best safety
standards but also shall be cost effective in the long run. Also, with the introduction of high speed trains
on several routes and the plans of the Indian Railways to join the high speed club shortly, the safety
aspect / elimination of level crossings must be studied in detail.
The construction of an under bridge is on progress at PHAPHADIH RAILWAY CROSSING. It is a
public underpass which is being constructed so that the regulation of traffic should be smooth and
continuous. It is being built to carry traffic volume across railway line at Phaphadih where we can't
physically or practically build a road. In our case we are using precast concrete units.

It is a box structure having a U-type retaining wall and a truss along with the concrete pavement. The
shape of the box is more or less rectangular.

1.2. PLANNING SEQUENCE FOR UNDER BRIDGE CONSTRUCTION:

✓ Identifying the need for the under bridge.
✓ Assessment of possible traffic.
✓ Study of location.
✓ Study of all possible alternatives.
✓ Short listing all possible alternatives.
✓ Identifying conceptual plans for alternatives. This involves finding materials, arrangement of
span etc.
✓ Preliminary design and cost estimation.
✓ Evaluation of alternatives its risk and the final choice of decision.
✓ Resource source identification by detailed surveying .
✓ Implementation with the help of documents. This is followed by carrying out by fixing the
agency, the construction details and their commissioning.

1.3. STEPS TO CONSTRUCT AN UNDERPASS

✓ Excavation of nearby area.

✓ Casting of main and auxiliary bed. They are casted side by side. Pin pockets must be provided at
suitable distance and in required number.
✓ Pre Casting of box.
✓ Pushing of box using hydraulic jacks over bed using pin pockets.
✓ Excavation of soil under railway track using cutting edge.
✓ After the box pushing is over the U-type retaining wall and along with base of the pavement is
constructed monolithically.
✓ Laying of the overhead truss.
✓ Finishing of pavement with the wearing coat.
Fig 1.1 Plan of the Under bridge to be constructed

Fig 1.2 Longitudinal Section of Road

2. SPECIFICATIONS AND PROCEDURES
2.1. SPECIFICATION OF A SINGLE BOX
✓ Outer dimensions of cross section of box (w x h) in (mm): 10100 X 7100
✓ Inner dimension of cross section of box (w x h) in (mm): 5500 X 8500
✓ Thickness of box in (mm): 800
✓ Material used for construction of box: RCC M-35
✓ RL of top of box: 98.246 m
✓ RL of bottom of box: 91.146 m
✓ Proposed road level: 92.446 m
✓ Cement Concrete used below wearing coarse: 350mm thick M-35
✓ Wearing course: 150 mm thick
✓ Camber provide for road: 2.5%
✓ Width of path way: 1m

PUSHED BOX

U-TYPE
RETAINING
WALLL

Fig 2.1 Specifications and Prepared box

2.2. PROCEDURE OF BOX PUSHING
A properly designed RCC thrust bed is casted at appropriate location. Generally the top layer of 50mm
is finished with screwing layer to obtain a perfect level surface. This thrust bed along with the connected
thrust walls and shear keys serves the purpose of forming the base to the casting of the box segments
and also enables jacking of the segments. It acts as a medium to transfer the entire jacking force into the
ground. The auxiliary thrust bed also may be constructed depending upon site requirement, which in
turn helps in saving of reinforcement, time, labor and expenditure.

AUXILARY BED

CURING OF MAIN
BED

HYDRAULIC JACK
PIN POCKETS

CONNECTION
OF JACK
PISTON
Fig 2.2 Thrust beds and shear keys
2.3. CASTING OF RCC BOX SEGMENTS
Over the well set and leveled thrust bed, RCC box segments are casted. The front face of the box will be
cast in a slope to match with the shape of the cutting edge which is fabricated from structural steel and is
integrated into the concrete. The cutting edge is provided all round the box and it also acts as a shield
preventing soil from top and sides from slipping. A rear shield is provided which houses and guides the
subsequent segments while supporting the soil. In case of more than one segment in a span, the
necessary recess arrangement with MS plate is provided at pre-determined locations while casting the
boxes for accommodating the jacks during pushing. An intermediate cutting shield with MS plate is also
required to be provided depending upon site conditions, type of soil, size of box etc.

Fig 2.3. Different stages of casting of box.

2.4. PUSHING OF BOX SEGMENTS

Under suitable speed restriction, the segments are jacked into the embankment by means of hydraulic
jacks of suitable capacity installed at the rear end of the segment taking reaction through an assembly of
steel pins and beams. Measures like GI drag sheets are provided to reduce drag effect and lateral
movement of overburden. Further epoxy coating on sides and top of the box segments is also applied to
reduce the soil friction. In order to reduce the friction between the thrust bed and box segment, two
layers of polyethylene sheet sandwiched with a coat of grease is provided. Grid arrangement with rails /
channels / timbers etc. was also provided at needy locations to ensure the safety especially in non-
cohesive type soils. Controlled blasting with due precautions is also carried out in case where rock is
encountered. The box is jacked into the embankment in a controlled and phased manner with
simultaneous excavation of material from inside manual / machinery after every stage of jacking.
Throughout the entire process of jacking, alignment is monitored by optical instruments at regular
intervals. Rectification of alignment is achieved through jacks. The jacking of segments, in case of more
than one in a span, first segment will follow the second segment for each stroke.
 Fig 2.4 Pushing of box segment with the help of piston

3. COMPONENETS OF CONTRUCTIONS
3.1. Thrust Bed

The thrust bed mainly consists of thrust wall, thrust bed with pin pockets on bed, keys for additional
resistance. The basic feature of the thrust bed is to provide necessary resistance needed for the jacking
operation. For this purpose, a well designed RCC slab will be constructed outside the bridge with its top
level being kept exactly at the proposed bottom level of the RCC box. Thrust bed will have suitable
pockets at different locations for housing jacking pins designed for resisting the pushing force exerted
by hydraulic jacks as the box is being jacked through the embankment. Over the thrust bed, 50mm
screed is to be provided to get exact line, level of the bed for pushing operation. At pockets location,
precast cover blocks are provided to cover the pin pockets during pushing operation.

Fig 3.1 Auxiliary thrust bed at site

3.2. U-Type Retaining Wall

Fig 3.2 Cross section of U-type retaining wall

SHEET TO PREVENT SHUTTERING OF

U-type
SEEPAGE OF RETAINING WALL
retaining
WATER
wall

Fig 3.3 Components of U-Type retaining wall

3.3. Front Shield

It is a mild steel 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.

3.4. Rear Shield

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.

3.5. Drag Sheets / Epoxy Coating

Drag sheets are provided at the top of box if required. Or the top of the box is coated with epoxy coating
to reduce the friction between the box and the soil.

Fig 3.4 Welding of the mild steel cutting edge

3.6. Drainage of Under pass
The proper network of drains must be provided in the under bridge so that water is not get accumulated
during rainy season. As under bridge is constructed below the GL of nearby location so the danger from
the seepage and accumulation of water is maximum.

Fig 3.5 Section of drainage

Fig 3.6 Drainage provide at site and seepage of water through box joint.
Joint where two
boxes join each
other
3.7. Pavement
It is the path over which the vehicles run. The load of the vehicles is directly bear by the pavement. It is
provided with dowel bars to uniformly distribute the stress. It is also provided with sheet to block the
seepage of water. The bottom of pavement is monolithically casted with retaining wall. It is provided
with wearing coat above.
 DOWEL BARS

PLASTIC SHEET
TO BLOCK
SEEPAGE

4. ADVANTAGES OF BOX PUSHING

✓ 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

5. DISADVANTAGES OF BOX PUSHING

✓ Needs trained staff and skilled supervision.

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

6. PROBLEMS ENCOUNTERED DURING BOX PUSHING

✓ Tilting of box.
✓ Shifting of longitudinal alignment.
✓ Failure of pin pocket.
✓ Leaking of joints.
✓ Occurrence of boulder layer.
✓ Occurrence of hard rock.
 ✓ Occurrence of collapsible strata.
✓ Unexpected floods during box pushing.
✓ Disturbance in track geometry.

7. SELECTION OF SITE DATA

✓ Topography of area.
✓ Detail cross section considering
✓ Rail level
✓ Formation level
✓ Width of embankment Ground level. Route of signaling cables, electric &telecom cables.
✓ Nearest river.
✓ Trail pit bore details, on embankment, on ground level.

8. Conclusion

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