Void filling

Badger Sett - embankment stabilisation without excavation

Challenge

Void formation and ground weakening within a highway embankment caused by badger sett activity led to surface settlement and full road closure.

Solution

Geobear delivered a targeted geopolymer injection solution to fill voids, stabilise weak soils, and restore structural support without excavation.

145 injections

Across multi-depth grid

4m

Treatment depth

Rapid reopening

No excavation required

Background

A local road crossing over a disused railway near Halberton experienced surface deformation, including visible depressions and the formation of an open void within the carriageway. Due to the narrow bridge geometry and safety constraints, the route was fully closed to vehicular traffic.

Initial investigation identified extensive subsurface voiding and extremely weak ground conditions beneath the carriageway. Dynamic Cone Penetrometer (DCP) testing recorded blow counts as low as zero to one, confirming a near-total loss of bearing capacity in localised zones.

The root cause was linked to extensive badger sett activity within the embankment. Prior to remediation, ecological mitigation works were undertaken, including relocation of the badgers and installation of protective measures to prevent reoccupation.

Challenge

  • Active voiding and ground loss caused by badger sett tunnelling
  • Extremely weak ground conditions with negligible load-bearing capacity
  • Restricted access due to narrow bridge geometry
  • Inability to safely maintain partial road access during repairs
  • Requirement to avoid destabilising adjacent structural elements (wing walls)
  • Environmental constraints associated with protected species relocation

Solutions

Geobear designed and implemented a targeted geopolymer injection scheme to address both void filling and ground improvement.

Design approach

  • Diamond grid injection pattern deployed across the affected area
  • Approx. 1m spacing in one axis and 2m in the other
  • Multi-level injection strategy:
    • Four treatment horizons between 1m and 4m depth
  • Controlled volume injection methodology:
    • Selected over “lift-to-refusal” approach due to inability to fully monitor adjacent wing wall structures
  • Final-stage injections incorporated laser monitoring to ensure controlled ground response

Material selection

A high-expansion structural geopolymer resin was selected due to its ability to:

  • Fill large and irregular voids
  • Penetrate granular soil fractions
  • Improve stiffness and load distribution within weakened zones

The treated ground comprised mixed soils with a notable granular component, allowing the geopolymer to both occupy void space and permeate surrounding soils, enhancing overall ground competence.

Side profile wing wall

 

Results

  • Complete void filling achieved, eliminating subsurface instability
  • Ground stiffness improved, restoring support to the carriageway
  • No excavation required, avoiding structural disturbance and heavy plant
  • Rapid mobilisation and installation, significantly reducing closure duration
  • Minimal disruption footprint, critical for constrained bridge environment
  • Controlled injection process, mitigating risk to adjacent structures

Verification included:

  • Structural monitoring of the bridge and embankment
  • Real-time laser monitoring during final injection stages

Why Geobear

Geobear’s solution was selected over traditional methods due to clear technical and operational advantages:

Speed of delivery

  • Installation completed in days rather than weeks or months
  • Rapid return to service for critical infrastructure

No excavation

  • Eliminated need for intrusive earthworks or reconstruction
  • Avoided risk to existing structures and services

Fast mobilisation

  • Lightweight equipment enabled deployment in restricted-access areas
  • Ideal for bridge and embankment environments

Lightweight material

  • Geopolymer adds negligible load to already compromised ground
  • Critical in weak or voided embankments

Ground improvement + void filling

  • Simultaneously fills voids and enhances soil strength
  • More effective than traditional grouting in heterogeneous soils

Environmentally inert

  • Chemically stable and non-leaching
  • Suitable for environmentally sensitive sites, including those involving protected wildlife

Minimal disruption

  • Small injection points (~16mm)
  • No large plant, excavation, or prolonged closures

Ready to discuss your project?

Get in touch with our expert team today and discover how Geobear can extend the life of your critical infrastructure assets.

Bear pointing Bear pointing