For official use only

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

GUIDELINES FOR CONSTRUCTION OF

LHS/RUB/SUBWAY BY RCC BOX AIR PULLING
METHOD

(April - 2024)

REPORT NO. BS – 137

ISSUED BY

B&S DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAKNAGAR, LUCKNOW-226011
 FOREWORD
Large numbers of Subways and Road under bridge (RUB) are constructed on
Indian Railways. The work is mainly executed by “cut and cover” method.
RDSO has issued typical drawings for Subways/RUB. Guidelines for
construction of RCC Road under bridge (RUB) and Subways by cut & cover and
through Box Pushing method have already been issued.

Railway Board vide letter no. 2022/19/CE-III/BR/RDSO/1 dated 19.10.2023,

had asked RDSO to prepare Guidelines for pushing/pulling RCC box under the
track with innovative techniques and modern equipment requiring lesser
requirement of traffic blocks and speed restrictions to enable faster
construction of RUB/Subways. Box Pulling method is an innovative technique
which can be used as a tool to enable faster construction of RUB/Subways. A
trial was conducted in Northeast Frontier Railway, where bridge no. 175 was
constructed in Araria-Galgalia newline project by using Box Pulling Method.

In order to maintain the uniformity and safe working in the field, guidelines of
construction of LHS/Box culverts by “Box Pulling” method is prepared.

It is expected that these technical guidelines for Box Pulling method will serve
as a technical guidance for officials of Engineering Department of Indian
Railways working in the field.

April, 2024

(B.P.Awasthi)
Principal Executive Director/Infra-II
 CONTENTS

SN TOPIC PAGE NO.

1 Introduction 1

2 Box Pulling Method 1-11

3 Prerequisites 11-18
GUIDELINES FOR CONSTRUCTION OF LHS/RUB/SUBWAY BY
RCC BOX AIR PULLING METHOD

1. Introduction
Presently, the following methods are used for construction of Road under
Bridges (RUB) and Subway in Open line (under running track):

a. Cut and Cover Method (Segmental boxes)

b. Box Pushing Method

c. Air Pushing Method (Box pushing with use of temporary girders)

d. Box pushing with protection plate arrangement.

Apart from the methods mentioned above, Box Pulling Method may also be
adopted in the field for construction of Road under bridges (RUB) and Subways.
Details about the Box Pulling Method are given below.

2. Box Pulling Method:

2.1 Background
A trial was conducted on N.F. Railway for construction of Bridge No. 175 (6.0m x
6.0m x14.0m RCC Box) using box pulling method for construction of RUB in
Araria-Galgalia new line project and a Report in this connection was submitted
by NF Railway to Railway Board vide letter No. W/362/CON/A-G/MISC/2023
dated 28.08.2023.

Vide letter No. 2017/7/CE-IV/88 dated 01.09.2023, Railway Board decided that
NFR, SCR, NR & WR should take up the construction of one RUB/LHS by Box
pulling method on trial basis on each Railway, preferably on single line section.
In the letter Railway Board advised, while selecting the site, the constraints
brought out in the report of NFR shall be kept in view and activities shall be
planned in details to ensure that there is no undue disruption to traffic in open
line. Railway Board directed nominated railways to submit a detailed report to
Railway Board after trial with suggestions for improvement in methodology, if
any considered during the trial.

Vide letter no. 2022/19/CE-III/BR/RDSO/1 dated 19.10.2023, Railway Board

also directed RDSO to prepare Guidelines for pushing/pulling RCC box under
the track with innovative techniques and modern equipment requiring lesser

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 requirement of traffic blocks and speed restrictions to enable faster construction
of RUB/Subways.

Construction of LHS/Subway of RCC box by Box Pulling method may be done by

two methods viz

a. Box pulling without use of RH girders, in this method only one traffic block is
required
b. Box pulling with use of RH girders, in this method two traffic blocks are
required.

2.2 Box Pulling without use of RH girders:

2.2.1 Pre block activities
a) Detail site survey is to be carried out for each RUB/Subway work separately. All
activities are to be undertaken before block. Pre block and Post block planning
should be done and outlined in advance.

b) Detailed soil investigation shall be conducted for calculating bearing capacity of

soil before starting of work. Extra care shall be taken while taking samples of soil
so that a realistic picture of soil stratum is obtained. It will be essential to take
soil samples in close proximity of cess.

c) Machinery, tools and plants and other equipment’s for excavation should be
arranged as per soil stratum observed in soil investigation. Relevant rules &
regulations of concerned State/Central Govt. authorities, especially where
blasting is envisaged in hard rock strata.

d) Side slope for excavation or cutting of embankment shall be decided based on the
type of soil strata observed in soil investigation.

e) S&T cable, electrical cable or any other cable or OHE wire infringing the way of
execution of LHS/RUB should be surveyed and planning for their
shifting/diversion, through concerned department be made.

f) Approach road for movement of road rollers & other heavy machineries be
planned in advance.

g) Ground to be prepared and any ground improvement if required may be done.

After improvement, levelling of ground shall be ensured by properly ramming or
rolling of ground surface.

h) Base slab of adequate length and width should be cast at appropriate location
and cured as per clause 8.4 of IRS Concrete Bridge Code 1997 (Reprint 2014).
Base slab shall be placed and levelled in advance on both sides excluding the

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 embankment portion only.

i) RCC box should be cast on one side of embankment on pre-cast base slabs with
lifting arrangement haunches on both sides at adequate distance and at
appropriate level in line with proposed location over a concrete bed and cured as
per clause 8.4 of IRS Concrete Bridge Code 1997 (Reprint 2014).

j) Manufacturing of rail cluster/sliding beam, rolling assembly of required capacity

shall be done in advance. Testing of rolling assembly for the particular load shall
also be done prior to operation.

k) Hydraulic vertical jacks of required capacity shall be procured / hired in advance

and testing of these jacks shall also be done prior to use.

l) Actual friction co-efficient between roller & rail cluster/sliding beam should be
evaluated for calculation of required pulling force by testing.

m) Preparing of winch machine foundation of proper capacity and fixing of winch

machine, shall be done.

n) Insertion of rail-cluster below the haunches of RCC Box on both sides shall be
done as per RDSO drawing no. RDSO/B-10160.

o) Proper fixing of rail cluster with the precast slab shall be ensured. Alignment of
rail cluster shall be kept straight and equally spaced with each other.

p) Levelling of rail cluster is an important aspect which shall be ensured. In case

there is unevenness, High density rubber pads of sufficient thickness may be
provided between pre-cast RCC slabs & rail cluster track to make it even.

q) Rolling assembly shall be placed over rail cluster by lifting the RCC box to the
required height with the help of hydraulic jacks.

r) After insertion and placing of rolling assembly over the rail cluster, RCC box
should be lowered with the help of jacks and placed over it.

2.2.2 Works during Traffic Block

a) Dismantling of track for a required length and cutting of embankment to required
length and depth. As a guideline side slope shall be kept 1:1.5 (V:H). In case of
dominantly non-cohesive soil, a flatter slope may be provided.

b) Continue the earth removal in layers of 500mm and shoring arrangements up to

the bottom of proposed base slab including thickness of sand layer.
c) Provide a sand layer of 200mm and proper compaction shall be ensured.
d) Preparation of bed for placing of pre-cast slabs at the excavated location.
Levelling of bed shall be ensured before placing of precast slab.

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e) Place the pre-cast base slab in position with helps of cranes on the compacted
bed.
f) Fixing of rail-cluster track on the pre-cast base slab. High density rubber pads to
be provided between pre-cast base slab & rail cluster, if there is any level
difference.
g) Simultaneously, pulling ropes to be fixed to the pulling hooks of the RCC box and
connected to winches.
h) Continuous pulling of RCC box will be carried out till its arrival at its desired
locations with the help of winch machine and rolling assembly.
i) After launching of RCC Box, rolling assembly including rail cluster shall be
removed with the help of hydraulic jacks.
j) Filling the sides of the box with earth and granular material. Compaction with
the help of light rollers to be ensured.
k) Placing and reconnection of track. Packing of track to be ensured before giving
track fit certificate at reduced speed as per extant instructions given in IRPWM.
Details of activities to be executed during Traffic Block are given below in table-1.

Table-1 Time Line for Single line track

(Assumptions: Size of RCC Box-6mx6m, Barrel length 8m, Zero earth cushion)

SN Activity Time (min)

1 Dismantling and Removal of track panel from track 10
2 Excavation of earth/embankment by two poclain with 70
*2.5m3 bucket capacity (one from each side) and dumping
of cut embankment material approximate 1000cum
3 Laying of sand below the base slab & preparation of bed 15
including levelling
4 Place the pre-cast base slab in position after preparation 30
of bed for placing of pre-cast slabs.
5 Fixing of rail-cluster track on the pre-cast base in the 45
excavated area.
6 Continuous pulling of RCC box will be carried out till its 60
arrival at its desired locations with the help of winch
machine and rolling assembly.
(For 30m Box pulling length with speed 30m/hour)
7 Rolling assembly including rail cluster shall be removed 20
with the help of hydraulic jacks after launching of bridge
8 Filling the sides of the box with earth and granular 20
material. Compaction with the help of light rollers shall be
ensured.
9 Placing and reconnection of track. 10
10 Exigencies and other minor work 20
Total 300

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Note:

1. * As per TATA HITACHI ZAXIS 400MTH model of similar bucket capacity available
in market.
2. Customised poclain bucket up to capacity 7.0 cum may be installed, which may
further reduce the cycle time involved in excavation of earth.
3. Volume of earth excavated depends on the formation height. Cycle time may vary
with the quantity of excavated earth according to the formation height.
4. Rolling assembly of higher load capacity (Hillman, Bemco etc) along with guide
support is available in the market, which will reduce the cycle time involved in
pulling of box.

2.2.3 Post Traffic Block

a) Packing of track in the approaches with appropriate ballast cushion as per
IRPWM shall be ensured before normalising traffic.
b) Restore normal speed in stages as per provision of IRPWM.

2.2.4 Various Stages of Construction:

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Page 6 of 18
Page 7 of 18
2.3 Box Pulling with use of RH girders:
RH girders may be used where availability of single long duration traffic block is
not possible. In such situations with the use of temporary girder traffic block
could be minimised and large number of activities can be planned without block
in restricted speed train operation.

2.3.1 Pre Block Activities

a) Detail site survey should be carried out for each RUB/Subway work separately.
Most of the activities should be undertaken before block. During block and post
block activities should be planned and outlined in advance.
b) Detailed soil investigation shall be conducted for calculating bearing capacity of
soil before starting of work. Extra care shall be taken while taking samples of soil
so that a realistic picture of soil stratum is obtained. It will be essential to take
soil samples in close proximity of cess.

c) Machinery, tools and plants and other equipment’s for excavation should be
arranged as per soil stratum observed in soil investigation. Relevant rules &
regulations of concerned State/Central Govt. authorities, especially where blasting
is envisaged in hard rock strata must be followed.

d) Side slope for excavation or cutting of embankment shall be decided based on the

Page 8 of 18
 type of soil strata observed in soil investigation.

e) S&T cable, electrical cable or any other cable or OHE wire infringing the way of
execution of LHS/RUB should be surveyed and planning should be done for their
shifting/diversion, by concerned department.

f) Approach road for movement of road rollers & other heavy machineries be planned
in advance.

g) Ground should be prepared and any ground improvement if required may be

done. After improvement, levelling of ground shall be ensured by properly
ramming or rolling of ground surface.
h) Base slab of adequate length and width should be cast at appropriate location and
cured as per clause 8.4 of IRS Concrete Bridge Code 1997 (Reprint 2014). Base
slab shall be placed and levelled in advance on both sides excluding the
embankment portion only.
i) RCC box should be cast on one side of embankment on pre-cast base slabs with
lifting arrangement haunches on both sides at adequate distance and at
appropriate level in line with proposed location over a concrete bed and cured as
per clause 8.4 of IRS Concrete Bridge Code 1997 (Reprint 2014).
j) Manufacturing of rail cluster/sliding beam, rolling assembly of required capacity
shall be done in advance. Testing of rolling assembly for the particular load shall
also be done prior to operation.
k) Availability of Hydraulic vertical jacks of requisite capacity shall be ensured
through procurement / hiring in advance and testing of these jacks shall also be
done beforehand.
l) Actual friction co-efficient between roller & rail cluster/sliding beam should be
evaluated for calculation of required pulling force by testing.

m) Preparing of winch machine foundation of proper capacity and fixing of winch

machine, shall be done.

n) Insertion of rail-cluster below the haunches of RCC Box on both sides shall be
done as per RDSO drawing no. RDSO/B-10160.

o) Proper fixing of rail cluster with the precast slab shall be ensured. Alignment of
rail cluster shall be kept straight and equally spaced with each other.
p) Leveling of rail cluster is an important aspect which shall be ensured. In case
there is unevenness, High density rubber pads of sufficient thickness may be
provided between pre-cast RCC slabs & rail cluster track to make it even.

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 q) Rolling assembly shall be placed over rail cluster by lifting of the RCC box to the
required height with the help of hydraulic jacks.

r) After insertion and placing of rolling assembly over the rail cluster, RCC box is to
be lowered with the help of jacks and placed over it.

s) Temporary girders and materials for temporary staging should be kept near the
site.

t) Temporary speed restriction of 20 kmph with necessary temporary engineering

indicators at the appropriate locations should be imposed.

2.3.2 Works during 1st Traffic Block:

a) Disconnect the track for a required length and cutting of embankment to
required length and depth. As a guideline side slope shall be kept 1:1.5 (V : H). In
case of dominantly non-cohesive soil, a flatter slope may be provided.

b) Earth should be removed in layers of 500mm and shoring arrangements up to

the bottom of proposed base slab including thickness of sand layer.
c) A sand layer of 200mm and proper compaction shall be ensured. Preparation of
bed for placing of pre-cast slabs at the excavated location. Levelling of bed shall
be ensured before placing of precast slab.

d) Place the pre-cast base slab in position on the compacted bed with the help of
cranes.

e) In the excavated area fixing of rail-cluster track on the pre-cast slab shall be
ensured. High density rubber pads to be provided between pre-cast RCC slab &
rail cluster track slab in case level difference is there.

f) Erect the steel cribs staging 'a' & 'b as per RDSO drawing no. RDSO/B-10160.

g) Erect the temporary girder on staging 'a' & 'b' as per RDSO drawing no. RDSO/B-
10160.

h) Link the track and allow traffic at restricted speed.

2.3.3 Works after 1st Traffic Block

a) Simultaneously, pulling ropes will be fixed to the hooks of the RCC box and
connected to winches.

b) Continuous pulling of RCC box will be carried out till its arrival at its desired
locations with the help of winch machine and rolling assembly.

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2.3.4 Works during 2nd Traffic Block
a) Disconnect the track.
b) Remove the temporary girder, staging 'a' &'b'.
c) Rolling assembly including rail cluster shall be removed with the help of
hydraulic jacks.

c) Fill the side of the box with back fill material as per clause no. 7.5.2 of
Substructure and Foundation code and compact.
d) Link the track duly providing ballast as required and allow traffic at restricted
speed.

2.3.5 Post 2nd Traffic Block

a) Packing of track to be done as required.
b) Restore normal speed in stages as per provision of IRPWM.

3. Prerequisites:
3.1 Rail Cluster:
Rail-Cluster shall be prepared as per drawing no. RDSO/B-10160. Three nos. of
52 kg S/H rails can be used for nesting and bolting together.

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3.2 Rolling Assembly:

Rolling assembly is required to be designed for sliding of RCC box on rail cluster.
Depth of flanges in the rollers shall be appropriate, so as to avoid de-tracking on
rollers during movement. The design of rolling assembly will depend upon size of
RCC box, barrel length of RCC box and total weight of RCC box etc. The number
of rolling sets depends upon barrel length & size of solid rollers. Rolling assembly
of adequate load capacity shall be designed and tested prior to use in launching
of bridge. Rolling Assembly set of 50T-100T load capacity may be designed.
Factor of safety shall be 1.25 while deciding the load capacity of rolling assembly.
High strength steel as per IS 1762 (Part-1):1974 and IS 2004:1991 shall be used
for manufacturing of rolling assembly. Coefficient Of friction shall be within the
range of 5-10%.

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Good quality customized industrial rolling assembly of Hillman inc. or similar
available in market with load capacity up to 150T and coefficient of friction is
limited to 5%.

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3.3 Built up stool (I-Section):
Built up stool should be designed as per super imposed load of RCC box
including side haunches. These stools are provided between bottom face of lifting
haunch & rollers. Details of Built up stool for 6.0mx6.0m RCC box is given
below.
Top & Bottom Flange plate - 290x25x1160 mm
Web Plate- 440x25x1160 mm and
Rib Plate-20mm thick @190mm c/c
Welding- SAW for Built up stool and GMAW for Rib plate
Grade of Steel- IS 2062 E250 B0

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3.4 Haunch:

Haunches are provided on both sides of vertical wall of RCC box for lifting off
purpose. Haunch should be designed for bearing total weight of RCC box. The
bottom surface of side haunch should be levelled and finished smoothly, if
needed by grinding. Haunches shall be provided on full barrel length of both
vertical walls.

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3.5 Pulling hooks on RCC box:

Pulling hooks are required to provide on both vertical wall at suitable location of
RCC box. Pulling hooks needs to be designed for higher pulling load. In order to
generate optimum pulling force, pulling hooks to be provided at same level with
the winch machine so that pulling rope could be kept horizontal in plane.
Anchorage length of hooks should be designed & checked. Development length of
bar is calculated as per Para 26.2 of IS 456.

3.6 Hydraulic Jacks:

Hydraulic Jacks are required for lifting of RCC box and placing of rolling
assembly including stool over rail cluster. Hydraulic jacks shall be placed at
equal distance and in equal number on both sides of the bridge. Jacks of
adequate capacity shall be provided. Capacity of jacks shall be governed by the
overall weight of RCC box. Number of jacks will be decided based on the capacity
of jacks and total barrel length of bridge. Overall capacity of jacks shall be
designed with sufficient margin of safety. If overall weight of bridge is 400T, then

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 recommended capacity of workable jacks shall be 400x1.5 (Margin of safety) i.e.
600 T. These hydraulic jacks shall be tested in advance.

3.7 Winch Machine:

Two winch machines are required for pulling of RCC box. Capacity of winch
machine depends on total weight of RCC box along with the complete rolling
assembly and friction co-efficient between rollers & rail cluster. Sufficient factor
of safety of 2.0 shall be adopted while deciding the capacity of winch machine. A
sample calculation is attached at Annexure-I to calculate requisite capacity of
winch machine.

*************

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 Annexure-I

CALCULATION OF CAPACITY OF WINCH MACHINE

Description Span Height Calculation

RCC Box of Size 6m 6m
Haunch 0.6m 0.6m
Lifting haunch 0.7m 0.65m
Wall thickness 0.65m 0.65m
Assumed Barrel Length 8.0 m
Area of box 17.29 m2
Area box haunch 0.72 m2
Area of lifting haunch 1.3 m2
Total area of RCC box 19.31 m2
Total volume of RCC box per metre 19.31 m3
Total weight of RCC box of full barrel length 386.2 t
Weight calculation
Total weight of RCC box of full barrel length 386.2 t
Built up Stool (I- section )weight 6.74 t
Rolling assembly weight 4.0 t
Total weight 396.94 t
Winch capacity calculation
Friction co-efficient between roller & Rail cluster 0.1
Required pulling force 39.7 t
Factor of Safety 2.0
Required pulling force with FOS 79.4 t
80 t
Total winch capacity required (Approx.)
No. of winch machines required 2
Capacity of single winch machine 40 t (min.)

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