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INDIAN RAILWAY INSTITUTE OF CIVIL ENGINEERING

Project Report

Construction of Road Under Bridge by Box


Pushing method using soil nailing technique for
stabilization of sandy soil
Session- 12104
Prepared & Presented By- M. K. Kinger AXEN/C/CSB-II(NR)
S. Oberoi
XEN/C/RMA(WCR)
Prakash Chandra ADEN/KVP(NER)

ACKNOWLEDGEMENT

Course Director
Sh. Nilmani
Professor/Track/IRICEN

Project Guide
Sh. Naresh Lalwani
Sr.Professor/Br-2/IRICEN

Introduction
A Road Under Bridge (RUB) was required to
be constructed by Northern Railway
Construction Organization as a part of ring
road bypass (constructed by PWD) from
Salimgarh fort to Velodrome road in
connection with Common Wealth Games2010. This road was proposed to move along
Bela road and pass under west end approach
of old Rail cum Road Bridge over river
Yamuna.

Salient features of work


Name of Work: Construction of Road Under Bridge
by Box Pushing Technique under railway tracks under
running traffic conditions at West End approach of old
Yamuna Bridge

Purpose: Development of Ring Road By Pass


Type of Structure: Box type Road Under Bridge
Nos. & Size of Boxes: 2 Nos.-10.50mx5.75m
1 No. -9.00mx4.00m
22m each box

Barrel Length:
No. of tracks to be crossed: 2 Nos.
Volume of Rail traffic:
Very heavy
Cost of Work:
Rs. 12.16 crores

Location of Work

RUB

Initial condition of Site of Work

Work finally required

General Arrangement Of Boxes

X-section through Retaining Walls

Arrangement of Thrust Bed

Details of Cutting Edge

Intricacies of the work


Boxes are required to be pushed through busy North &
South line which carry about 150 passenger trains and 50
goods trains a day.
Boxes are required to be pushed through 7.50m thick
cohesion less silty sand strata sandwiched between gravity
type random rubble stone masonry retaining walls on
either side. Silty sand strata is prone to collapse when cut
to unavoidable steep slope during box pushing.
Retaining Wall on Exit End was likely to bulge in face of
approaching box during pushing.
Controlled dismantling of random rubble stone masonry
retaining walls to cause least disturbance to sandy strata.
This is a case of Box Pushing in Zero Tolerance Zone
and in highly unfavourable Soil strata.

Remedial Measures
Soil Stabilization: It has been achieved through
Soil Nailing technique designed by CRRI.
Pipe Arch Roofing: It has been adopted to
prevent the surcharge/cushion soil from caving in
during box pushing.
Gravity type stone masonry retaining walls: Its
X-section and depth has been ascertained by GPR
exploration to check :
o Feasibility of construction of thrust bed.
o Internal batter particularly in front retaining wall.

Remedial Measures
Cutting Edge: Conventional design has been
modified to have longer cantilevering front portion
strong enough to withstand train load and to
facilitate comparatively flatter slope of cut during
pushing.
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.
Steel Support System: It is designed to prevent
bulging of rear retaining wall in face of
approaching box

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.

CRS sanction was obtained and Speed restriction of 20 Kmph + Stop dead ,if
required, was imposed.

Relieving Girders-12 nos., each 12 m long, were fabricated.

Details of Soil Nailing System

CRRI used GEO 4 software for designing the nailing system.

Input parameters:
Live Load: 110 kN/m on each track.
Geometry of cut slope: Inward slope -83o
Depth of Over burden above box: 1m

Soil Properties:
o Angle of internal friction: 29o
o Bulk density of soil:17 kN/m3

Nail Parameters:
Type of nail

Design values of Pull-Out


strength (kN/m)

Grouted Nails

Driven Nails

Configuration of Soil Nails


Inside the Box:
o In front of periphery: 3 driven nails-15m
long in each row.
o Inside Box (in remaining area):
A grid of 35x15(525 driven nails) &
30x11(330 driven nails) were provided in
bigger and small boxes respectively

Configuration of Soil Nails


Outside Box:
Top of Box:
o 25/22 grouted nails-15m long provided for bigger
& small boxes.
o 31/26 driven nails-15m long provided 250mm
below grouted nails

Side of the Box:


o One column of grouted nails-15m long provided
in gap of 500 mm between boxes

Details of soil nails for Box-3(small box)


Row
No.

Type

Dia
Nos. Spacing (m)
(mm)
Vert. Hor.

Length (m) Total Length


(m)

Grouted

89

23

0.5

15

345

Driven

32

27

0.25

0.4

15

405

3 to 5

-do-

32

36

0.3

0.3

15

1620

6 to 8

-do-

32

36

0.3

0.3

8.30

900

9 to 18

-do-

28

36

0.4

0.3

6.30

2270

Side

Grouted

89

14

0.5

15

210

Summary of Soil Nails provided


Box No. 1 & 2 (bigger boxes)
Total Nails: 893 Nos. (42 Nos. Grouted + 851 Nos. Driven)
Total Length of Nails:7575m (630m Grouted + 6945m Driven)

Box No. 3

Total Nails: 640 Nos. (37 Nos. Grouted + 603 Nos. Driven)
Total Length of Nails:5750m (555m Grouted + 5195m Driven)
Grand Total Nos. of nails in all three boxes= 2426 Nos.
Grand Total length of nails in all three boxes= 20,900 m

Test Soil Nails being installed using


heavy duty hydraulic Pusher

Mr. Rakesh Chopra, Member


Engineering, inspecting soil nailing work

Soil Nails installed for


stabilization of sandy strata

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 gas
cut/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.

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.

Following precautions are required to be taken:

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.

Construction of Thrust Bed in


progress

Construction of Box Segments

Jacking Arrangement

End Support Frame for provision


of Drag Sheets

General arrangements made for


provision of Drag Sheets

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

Steel support system erected for


protection of rear gravity retaining wall

GPR Data collected by NogginPlus 250


SmartCart System for determination of Xsection and Depth of Retaining Wall

Rammer in operation to drive soil


nails

Mr. Vivek Sahay, Member Traffic along with


COM/NR inspecting site and is highly satisfied
with safety afforded by soil nailing technique.

Steel support system members being


driven into ground with vibratory rig

Mrs. Sheila Dixit, CM/Delhi


viewing progress of work

Cutting Edge is coming out of rear


Retaining Wall indicating fast
approaching end of pushing operation

Appreciation of work

THANKS

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