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Rail depot foundations strengthened without mini piling

Challenge

Crossrail required increased bearing capacity beneath new rail depot foundations. Conventional mini piling was proposed, but the project demanded a faster, lower-disruption solution that would minimise programme delays and site impact.

Solution

Geobear strengthened the existing ground using engineered geopolymer injection beneath foundation pads and strip foundations, achieving the required bearing capacity within 10 days, verified through independent plate load testing.

19

Pads strengthened

168 m

Strip foundations improved

10 days

Programme time

Background

As part of the redevelopment of Ilford Rail Depot for the Crossrail programme, new maintenance facilities required foundation improvements to support additional structural loads. The existing ground consisted of sand and clay deposits that required strengthening before construction could proceed.

Conventional mini piling was initially considered to increase the bearing capacity beneath the proposed foundations. However, the project team sought a solution that would minimise programme duration, reduce disruption and avoid the complexity associated with piling works.

Following an engineering assessment, Geobear's geopolymer ground improvement solution was selected as a faster and more efficient alternative.

Challenge

The project required ground improvement beneath 19 isolated foundation pads and approximately 168 metres of strip foundations while maintaining a demanding construction programme.

The engineering solution needed to:

  • Increase bearing capacity to 350 kPa
  • Improve variable sand and clay ground conditions
  • Minimise disruption to the construction programme
  • Reduce the need for excavation and spoil removal
  • Provide independently verifiable engineering performance

A traditional mini piling solution was estimated to require approximately six weeks to complete, creating significant programme implications.

Solutions

ilford-injection

 

Geobear designed a bespoke geopolymer injection solution to improve the engineering properties of the existing ground beneath the proposed foundations.

The expanding geopolymer resin was injected through small-diameter holes, compacting weak soils and increasing bearing capacity without excavation or the installation of deep piles.

Treatment was carried out to depths of up to 5 metres, targeting the weak strata beneath both isolated pad foundations and strip foundations.

The solution was independently verified using pre- and post-treatment plate load testing to confirm that the required design bearing capacity had been achieved.

plate-load-testing

Results

The project was completed in just 10 days, compared with an estimated six-week programme for conventional mini piling.

The required 350 kPa bearing capacity was successfully achieved across all treatment areas, allowing construction works to proceed without delay.

By improving the existing ground rather than transferring loads to deeper strata, the project avoided the disruption typically associated with piling operations, including extensive excavation, spoil removal and large construction plant.

The compact equipment also enabled efficient working within the constrained rail depot environment.

Why Geobear?

Compared with conventional mini piling, Geobear delivered:

  • Completion in 10 days instead of approximately six weeks
  • No excavation or spoil removal
  • Minimal site disruption
  • Compact equipment suitable for restricted working areas
  • Independently verified bearing capacity improvements
  • Faster return to construction activities

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.

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