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M42 and M54 slab stabilisation

Challenge

Concrete slab sections on the M42 and M54 experienced loss of support and voiding, requiring stabilisation without extended lane closures or major traffic disruption.

Solution

Geobear used precision geopolymer injection to fill voids and restore slab support, delivering rapid stabilisation within live motorway constraints.

Strategic motorway network

M42 and M54

Slab support restored

Voids filled beneath carriageway

Live traffic environment

Minimal lane closures required

Background

Sections of concrete carriageway on the M42 and M54 were affected by void formation and weakened sub‑soils beneath slab panels. Loss of uniform support risked further settlement and reduced pavement performance.

Given the strategic importance of these motorways, maintaining traffic flow during remediation was critical.

Challenge

Traditional slab removal and reconstruction would have required extended lane closures, significant traffic management and increased programme duration.

A fast, controlled method was required to restore ground support in situ while minimising disruption to road users.

Solutions

Geobear implemented a targeted geopolymer injection programme beneath affected slab sections.

Small‑diameter injection points were drilled through the carriageway, allowing a two‑component geopolymer to be introduced into voided and weakened zones. As the material expanded, it filled voids, compacted loose soils and restored continuous support beneath the slabs.

Injection was monitored in real time to ensure precise control and prevent over‑lifting.

Results

Uniform support was reinstated beneath the slab panels without excavation or reconstruction.

Works were completed efficiently within live motorway conditions, delivering a durable and lower‑carbon alternative to traditional repair methods.

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