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Emergency water sealing for Sheikh Zayed Road excavation

Challenge

Rapid groundwater ingress flooded a deep excavation beneath Sheikh Zayed Road (E11), Dubai’s busiest highway. The water flow threatened to wash out the soil supporting the motorway and the adjacent Dubai Metro viaduct, posing a risk of catastrophic subsidence and road closure.

Solution

Geobear deployed an emergency response team to inject a fast-curing, hydro-insensitive geopolymer. The material sealed the fissure instantly, stopping the water flow and stabilizing the ground without disrupting traffic.

8 meters

Depth of the excavation where the leak occurred

0

Disruption to Sheikh Zayed Road traffic or Dubai Metro services

Emergency

Rapid mobilization to prevent soil washout

Background

A major civil engineering firm was constructing a utility duct underneath Sheikh Zayed Road using a mini tunnel boring machine. The excavation pit, located adjacent to the E11 and the Dubai Metro viaduct, was shored with sheet piling.

However, the UAE’s rising water table presented a challenge. The vibration restrictions (due to the nearby Metro) meant hydraulic pile drivers could not be used, leading to imperfect interlocking of the sheet piles.

As the excavation reached the sandstone layer, groundwater began gushing through the gaps at a rate that overwhelmed three industrial pumps.

Challenge

The rapid water ingress created two critical problems:

1. Project halt: The flooding stopped all tunneling work, causing costly delays.

2. Subsidence risk: The water flow was carrying fine soil particles with it (washout). Continued leakage would eventually create voids beneath the E11 highway and the Metro piers, leading to settlement, structural failure, and the unthinkable closure of Dubai’s main artery.

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Attribution

Solution

View of open construction pit at side of Sheikh Zayed highway

The contractor required an immediate solution to seal the leak without heavy machinery.

Geobear deployed a specialist two-component hydro-insensitive geopolymer.

Access: A technician was lowered into the 8m deep pit in a safety cage.

Injection: We injected the resin directly into the active flow path (the gap between the rock and sheet pile).

Reaction: The material is designed to expand and harden in seconds, even in flowing water. It filled the void, bound the loose soil, and created an instant, permanent water barrier.

Results

The intervention was an immediate success.

Leak sealed: The water seepage was drastically reduced, allowing the site pumps to drain the pit effectively.

Asset protection: The risk of soil washout under the highway was eliminated, protecting the E11 and Metro foundations.

Project resumed: The main contractor was able to proceed with the tunneling works safely.

Water ingress threatening your excavation?

We stop active leaks and seal shoring walls instantly. Fast emergency mobilization available.

Request emergency support
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