Method Statement for LHS Casting & Pushing

METHODOLOGY
A. Activity before Excavation for Thrust Bed:-
a) Before commencement of any Excavation work for thrust bed casting we have to ensure
safety/protection of different (S&T)/ electrical cables.
b) Firstly cable should be located with the help of cable locator in presence of PMC/RVNL /open line
representatives.
c) Manually digging should start after confirmation of cable location.
d) By digging in sufficient length we have to take it out all live/dead cable.
e) Thereafter the cables either shifted or protected with RCC/PVC pipes to avoid any damage to the
cables.
f) In case of straight location i.e. if LHS will be commissioned on existing LC location then closer
permission of LC will be taken from state authority.

B. THRUST BED:
The thrust bed consists mainly of, Anchor 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. Excavation for construction of thrust bed will be done on existing track side at about 9.625 M
away from the center of existing track. 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. The typical structural components of the thrust bed proposed to
be adopted for the project are shown in Fig-01.

Fig 01

C. RCC Box Casting:

The RCC Box is cast in situ of different lengths as per approved GAD. Before casting of RCC box one layer
of grease will be applied over thrust bed and then we will lay one layer of polythene sheet over it after
that one more layer of grease will be applied over polythene sheet then second layer of polythene sheet
will be laid.

Fig no: 2: PRECAST BOX SEGMENT

D. FRONT SHIELD:

It is fabricated for cutting action and to provide support, to prevent caving of soil. The front shield which
acts as a Cutting edge will be provided at the front of the first box unit to be jacked. This shield will be
fixed to the RCC box through proper anchorage in the box walls with required projection from the face
of the box. The end of the box itself is cast in a slope with horizontal projection of required length and
the front cutting shield is provided with a projection of @ 1000mm or more as needed, covering the
entire periphery of the box. Thus the main feature of the cutting edge is not only to cut the soil, also to
retain the soil above the cutting edge.

E. REAR SHIELD:

Rear shield fabricated from mild steel will be fixed on rear end of the first unit of the box. This shield will
be fixed to the RCC box through proper anchorage in the box walls and slab with a projection of 400 to
600 mm. covering entire periphery of the box at the time of casting of the box. It is provided by
anchoring steel plates on the face of bottom slab of RCC box to suitably distribute the jacking load of
Total pushing length. The Box section is designed as per IRS / IRC codes of practice for loading. Concert
grade as per Design/Drawing of LHS Box. There will be one more provision for site shield which will
protect soil to induce in the gap between two boxes during pushing activity.
F. PIN POCKETS:

 Pin pockets of 0.5m x 0.50m x 0.6m size are provided at suitable spacing for jacking
arrangements. The sides of pin pockets are provided with 5mm thick M.S Plate to take the
thrust.
 The pin pockets are then filled with sand and small layer of screed concrete is placed on them to
get smooth surface for casting of Box.

Fig no 6: PIN POCKET

G. RCC box Pushing: Jacking operation will facilitate with the help of adequate capacity of hydraulic
jacks. Before starting of box pushing we have to erect temporary protection arrangement below the
running track and it will be joint/connect with anchor wall. The technique of box jacking consists of
construction of an RCC thrust bed with necessary jacking pin holes. Steel pins are embedded in the
thrust bed over which the boxes will be cast in units and will be jacked by applying pressure through
hydraulic jacks which takes reactions against the jacking pins inserted in the pin holes left in the thrust
bed.

Fig no: 7: PINS

The front unit will be provided with a cutting edge (front shield) and the subsequent units will be
provided with intermediate jacking stations at their junction points. Length keeping the front shield top
well embedded in the embankment soil at all times. Excavated soil then be removed manually and box
will be pushed by jacks slowly in the gap created. The box will be pushed by hydraulic jacks operated by
power pack. This operation of jacking will be continued by adding suitable steel packing boxes and plates
between jacking pins and hydraulic jacks till the next row of the pockets in thrust bed is exposed. The
jacking pins will then be inserted in these pockets and pushing will be continued till the first segment of
box is completely pushed in the embankment.

H. Activity before & after Pushing of Box:-

Pre Block Activity: -

1) Caution of 20KMPH will be imposed two days before of jacking operation.

2) During caution we will remove ballast from location where temporary protection will be erected.

3) Protection segment should be placed at site near LHS.

4) During pushing LHS assistance required from Railways such as: -

a) Nomination of PWI for block taking and cancellation,

b) 2 nos. watch out men,

c) OHE gang for taking power block,

5) Additional resources to be deployed during LHS pushing are as follows: - a) Gas cutting kit, b) 8 no.
wooden sleeper, c) P way gang 25 men, d) P way T&P (2 nos. cutting machine, e) 2 nos. hole machine,
f)1 no. drill machine.

During Traffic Block Activity: -

1) Track cutting will be done by using track cutting machine.

2) Track will be removed during traffic block.

3) The ballast cushion under sleeper will be removed & formation will be leveled.

5) 25mm Thick sand layer will be laid on formation as leveling course.

5) Protection segment fixed on it as per direction of Engineer In-Charge.

6) All segment joints bolted as shown in drawing.

7) Rubber pad of 10MM will be provided above ISHB 150 before lying of track.

8) Track will be placed & connected by joggled fish plates (2 No. per set) with 4 pair clamps, 4 No. Bolts
& Nuts and 8 Nos. special washers.

9) Block will be cleared followed by speed restriction of 20KMPH.

Post Block Activity: -

1) Speed restriction of 20KMPH will be imposed for minimum 30 days.

2) The ends of bottom and top MS plate will be anchored with adequate size joist already fixed with
anchor.

3) Protection arrangement below both tracks will be connected together if required.

4) Pushing will be carried out till completion.

5) Pushing of Box :-

a) Per day length will be executed 2-3 mtr.

b) Pushing will be carried out from 6:00 AM to 6:00 PM on daily basis.

c) Pushing activity will be carried out under supervision of RVNL & PMC.

d) Precaution during pushing- 2 no's of gang man should visit to ensure level of both track with the help
of spirit level and to ensure fishplate will be fix for jointing rail.

f) Ramp construction work will be carried out.

6) On completion of pushing joints between boxes will be sealed with epoxy.

7) After completion of box pushing one more traffic blocks are required to restore protection
arrangement for that we will Remove track, Remove protection arrangement, Lay Ballast, Link track and
after that Alumino thermit welding of 60kg/52 kg rail joints or combination joints of 60kg/52kg rail by
pre-heat (SKV) welding technique.

8) Clear traffic block.

Safety Requirements:

 All the safety norms and precaution shall be taken for each activity clearance shall be taken
before commencing.
 Workman to be engaged after Screening, giving Safety induction & medical test etc.
 Every workman shall be allowed to work with Personal Protective Equipment (safety shoes,
Safety Helmet, Reflective Jackets, hand gloves etc.)
 In case of working close to the existing railway tracks, proper barricading will be done as per
approved drawing before commencement of work.
 No machinery will be permitted to move close to existing rail tracks. In special cases where the
machinery is required to move close existing tracks, proper safety precautions has to be put in
place in consultation with Rly. officials.
 Proper equipment & vehicles shall be deployed for the job.
 Operators having valid license to operate the equipment's.
 Lifting equipment, crane/hydra, tools and tackles shall have third party load test certificate from
competent person.
 Person shall not be allowed under the suspended load while lifting load.
 Safety warning signs shall be placed to provide adequate warning
 Adequate lighting shall be made available in case of night work.
 Various unexpected situations are likely to occur during the box pushing operations. Since the
safety of running trains is directly affected, proper planning and implementation is essential for
smooth completion of work. Advance analysis of site, likely problems that may arise and
planning to tackle the same will help the executive for speedy and safe completion of the work.