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M42 – Geobear saves money keeping UK’s roads running

Challenge

Settlement and voiding beneath the M42 carriageway required remediation to maintain safety and performance while avoiding prolonged closures and high reconstruction costs.

Solution

Geobear delivered precision geopolymer injection to restore ground support and stabilise slabs, reducing programme time and overall cost compared with traditional reconstruction.

Strategic motorway asset

M42 carriageway

Cost‑effective solution

Reduced reconstruction expenditure

Live traffic environment

Minimal disruption to road users

Background

Sections of the M42 were experiencing void formation and reduced support beneath concrete slabs. Left untreated, continued settlement would have affected ride quality and long‑term pavement durability.

As part of the UK’s strategic road network, maintaining traffic flow and controlling costs were key project drivers.

Challenge

Traditional slab removal and reconstruction would have required extended lane closures, significant traffic management and higher carbon impact.

The client required a fast, controlled and cost‑efficient alternative that could restore structural support while keeping the motorway operational.

Solutions

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

Small‑diameter injection points were drilled through the carriageway to introduce a two‑component geopolymer into voided and weakened zones. As the material expanded, it filled voids, compacted loose soils and re‑established uniform support.

Injection was monitored in real time to ensure accurate control and effective stabilisation within tight programme constraints.

Results

Ground support was restored without excavation or full slab reconstruction.
The solution reduced disruption, shortened programme duration and delivered significant cost savings while keeping a key UK motorway running safely.

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