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Concrete bay stabilisation – M54 J3–J2

Challenge

Concrete pavement bays between M54 Junctions 3 and 2 were experiencing settlement and loss of support, creating ride quality issues and requiring rapid stabilisation without motorway closure.

Solution

Geobear delivered targeted geopolymer injection beneath affected bays, restoring support, improving load transfer and enabling traffic to resume quickly with minimal disruption.

Motorway location

M54 westbound between J3 and J2

Concrete pavement bays treated

Targeted stabilisation approach

Rapid return to service

Trafficable shortly after injection

Background

A section of the M54 concrete carriageway between Junctions 3 and 2 was exhibiting signs of differential settlement. Loss of sub-base support beneath several pavement bays had resulted in voiding and reduced load transfer performance.

Given the strategic importance of the route, a solution was required that would restore structural integrity while maintaining network availability.

Challenge

Traditional break‑out and replacement would have required extensive traffic management, prolonged lane closures and significant programme duration.

With high traffic volumes and limited access windows, the scheme demanded a fast, technically robust solution that could be delivered safely within restricted working periods.

Solutions

Geobear implemented a precision geopolymer injection programme to stabilise the affected pavement bays.

Small‑diameter injection points were drilled through the concrete slabs and the two‑component geopolymer was introduced beneath the pavement. Upon mixing, the material expanded to fill voids, densify the underlying strata and restore full contact between slab and sub-base.

Injection was carefully controlled to ensure uniform support and, where required, managed re‑levelling of the slabs. The rapid curing characteristics of the geopolymer enabled treated areas to be reopened to traffic within a short timeframe.

Results

Structural support was restored beneath the affected concrete bays, improving load distribution and ride quality.

The works were completed within tight operational constraints, minimising disruption to motorway users while delivering a durable, low‑carbon alternative to reconstruction.

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