TechBox™ – A Major Innovation

TechBox™ is recognized as a revolutionary method for rapid construction in the field of civil engineering. This system provides numerous structural solutions for owners and clients ranging from cut ‘n’’ cover bridges, tunnels, underpasses, overpasses, culverts and portals.

As a world leader in specialized civil engineering, Terre Armée Internationale has a worldwide presence and has the advantage of both local and international expertise. In 1980s the company first launched the prefabricated arch technology as a modern structural solution to growing infrastructure needs.

Reinforced Earth® India has revolutionised structural design and is applicable for all kinds of structures in:• Roadway and Highway• Railway• Marine and waterway• Industrial, energy and mining infrastructures• Protective structures

TECHBOX™

Terre Armée Business Lines

Integrating Engineering Solutions

REGISTERED OFFICE Reinforced Earth India Private Limited

E 11, Block B-1 Extension (Opposite NTPC Badarpur) Mohan Co-operative Industrial Estate, Mathura Road, New Delhi 110044 T +91 11 4645 7600 - 7601 | F +91 11 4645 7630 E reinforcedearth@terrearmeeindia.com | W terre-armee.com

ZONAL OFFICE Bengaluru | Kolkata | Mumbai

TechBox™

T echBox™ is a state-of-the-art articulated precast concrete ‘BOX’ system developed by Terre Armee.

Terre Armee has developed expertise in optimizing Soil Structure interaction mechanics to minimize section sizes and allow rapid on-site regulated installation

with precast units for buried ‘box’ structures.

The TechBox™ system is based on precision-made Precast Concrete modular elements comprising free standing walls and over bridging units and has all features and advantages similar to that of TechSpan®.

This system comprises free standing walls and over bridging units for TechBox™ that are generally clear envelops (≥5mx3m) or can be a modular single unit elements, for small size box known as TechCulverts®.

The structural design can be modeled on an elasto-plastic soil model with soil stiffness and elasticity parameters in FEM analysis.

TechBox™ is generally applied to clear envelops exceeding 5m x 3m and is suitable for the following applications• Any cut and cover box structures, single or multi-span units.• Vehicular and Cattle / Pedestrian underpasses (VUPs and CUPs /

PUPs) on highways or railways in cuttings & at grade.• Small / minor bridges in highways/railways.• Channel covers in irrigation projects.

• Aesthetic: The standardized precast process ensures a better finish. A variety of facing finishes can be incorporated.

• Safety: Since TechBox™ is precast, it is easier to organize and standardize safety procedures.

• Global experience: TAI Group of companies and subsidiaries have global experience in TechBox™ structures that support local expertise.

• Sustainability: Using thin sections results in lesser consumption of concrete, reducing carbon emission, making TechBox™ environmentally sustainable.

• Cost Effectiveness: Overall cost is at par or lower compared to conventional methods.

• Faster Construction Time: The standardized method reduces construction time by 50-60%.

• Technical Quality: This FEM analysis design follows a standardized precast process ensuring better quality and superior durability.

• Construction Advantages: This system ensures more orderly sites with less disruptions to traffic.

Single Box AlternativesA. Underpass with two precast side walls as abutments or

TechWall®, top beam and slab. Cast-in-place foundation for abutments.

Small BoxTechCulvert® is an inverted “U” forming a Box. It is generally applied for clean envelopes not exceeding height of 3m and span of 6m.

Twin TechBox™Twin TechBox™ is a double open precast concrete box system that combines five units, consisting of three wall units and two slab units.B. Conventional box with two precast side units and top slab.

Base slab is cast-in-place.

TechBox™ Advantages

Types of TechBox™

Construction Sequences

3

Reinforcement for Slab-Stitching (for stich two top-slab unit)

Reinforcement for Stitching-Beam (to stitch wall and slab unit)

1 2

1

4 5

2 3

Reinforcement for Base-Slab Casting

TechBox™

Installation of side wall Step – 1 Repeated Erection of top slab

Casting of base slab Lining for preventing seepage

Stage backfilling up to stitch beam level Casting of side stitch beam Finishing

Preparation of bed Installation of precast unitStep 2 repeated to complete the required length

TechCulvert®: Box Type Installation

Lining for preventing seepage Stage backfilled & completed

6

1

7

2

8

3

4 5

Methods1 Lifting System of the Units• At Casting & Installing Yard - Cranes are used to lift both

Wall & Slab units.• For Wall units Debedding and Rotation Lifting Anchors on side

and for Installation Lifting Anchors at top are used.• For Slab Units both unmoulding and installation is done by

Lifitng Anchors using Spreader Beam.

2 Transportation of Units• Both Wall & Slab Units are transported from Casting Yard to site

on Flat Bed trailers of suitable capacity. • It is important to note that weight and dimension requirements

for hauling truck selection is needed, and over long distances this may add to cost.

• One designated trailer fitted with wooden dunnage is usually kept for placing Slab Units. Slab Units are shifted one at a time.

3 Installation of Precasted Units• The average time for site preparation and installation of wall

& slab units for one underpass takes around 12-15 days. • For in-situ casting of the stitch beams on either side along with

the cast in-situ raft time requires around 20-25 days.

4 Safety• Special attention needs to be given to Safety during the entire

work process. A detailed site specific risk assessment has to be done for all activities to ensure safety at all times.

• Through daily work pre-construction meetings along with periodic tool box training and safety audits at regular intervals to overcome associated risks during construction.

Special Features The TechBox™ precast boxes have various advantages over conventional systems. TechBox™ provides dimensional uniformity in precast units, superior quality under controlled environment and most importantly the ease of site installation. The important feature of TechBox™ system is the integrity achieved by stitching the different units together and hence improving its performance under different load condition including seismic.

Outcome• The TechBox™ system has proven to be a superior product

alternate to the conventional in-situ box system. • The TechBox™ system is a time saving alternative to

conventional systems.• The opening size of the TechBox™ structures have been

customised to meet client‘s requirements. • More efficient use of manpower and use of prefabricated moulds

reduces labor costs as a motivation for using TechBox™.• Superior product quality may be achieved by using TechBox™

precast boxes.