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Stabilizing a critical substation foundation for Fugro in JAFZA

Challenge

A subsiding foundation at a low-voltage substation in the Jebel Ali Free Zone posed severe operational risks and the threat of power disruption for Fugro.

Solution

Geobear utilized non-intrusive geopolymer injection to bind loose soils and fill voids, restoring the foundation's load-bearing capacity in just five shifts without operational downtime.

5 shifts

Total time on-site to complete the stabilization

0

Operational downtime or power disruption

100%

Non-intrusive process requiring no heavy excavation machinery

Background

Fugro, a leading global provider of Geo-data solutions, operates a facility in the Jebel Ali Free Zone (JAFZA). They identified severe ground stability issues affecting a low-voltage substation on the site. The substation’s foundation was experiencing subsidence, posing a direct risk to the sensitive low-voltage equipment and creating the potential for a power supply disruption that could impact their wider operations.

Challenge

The primary technical challenge was the subsidence of the substation foundation caused by weak underlying soil conditions. The client required a solution that could address the root cause of the settlement without the need for disruptive civil works. Traditional methods like concrete underpinning or piling would have required heavy excavation machinery, significant site clearance, and a prolonged construction period, which would have inevitably disrupted Fugro’s critical activities and potentially required a power shutdown.

We faced serious challenges with our substation’s stability... Geobear stood out with its cost-effective, environmentally friendly, and non-intrusive approach.

David Duguid, Facility Manager, Fugro

Geobear treatment container being carried to site via front loader on sandy ground.

Solution

Geobear started with a site investigation to identify the specific causes of the subsidence. Utilizing this data, our in-house engineering team developed a customized treatment plan. The execution involved drilling small-diameter holes through the existing foundation and into the affected ground. We injected a specified quantity of expansive geopolymer resin into these points.

The geopolymer expanded rapidly, filling voids and binding the surrounding loose soils. As it hardened, it improved the load-bearing structure under the foundation, all achieving stability without the need for excavation.

UAE side of villa with brickwork removed and injection tubes inserted into the soil.

Results

The project was completed in just five shifts with zero operational downtime, allowing Fugro to continue its activities uninterrupted. The non-intrusive approach proved to be a cost-effective alternative to traditional ground stabilization techniques, significantly reducing overall project expenses while eliminating the risks associated with heavy construction work near live power assets.

"We faced serious challenges with our substation’s stability... Geobear stood out with its cost-effective, environmentally friendly, and non-intrusive approach. Their team delivered an excellent solution without any disruption to our operations."
— David Duguid, Facility Manager, Fugro

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