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WCML Shugborough tunnel – shaft and annulus void filling

Challenge

Voids within the shaft and annulus at Shugborough Tunnel on the West Coast Main Line posed risks to structural integrity and rail safety.

Solution

Geobear delivered precision geopolymer injection to fill annulus and shaft voids, restoring ground support and stabilising the structure without disrupting rail operations.

Live rail environment

No disruption to train services

Shaft and annulus voids filled

Ground stability restored

Rapid, non‑intrusive method

Minimal access requirements

Background

Tunnel shafts and annular voids can develop due to historic construction methods, ground movement or washout over time.

On critical rail infrastructure such as the West Coast Main Line, maintaining structural integrity and operational safety is essential.

Traditional excavation or intrusive repairs can require extended track possessions and significant disruption.

Challenge

Investigations at Shugborough Tunnel identified voiding within the shaft and surrounding annulus, raising concerns over long‑term stability.

A solution was required that could be delivered within strict rail access constraints while ensuring precise treatment of the affected areas.

Solutions

Geobear designed a targeted geopolymer injection programme to treat the identified voids.

The expanding resin filled cavities, improved soil stiffness and re‑established uniform support around the shaft structure.

All works were carefully controlled and monitored to suit the live rail environment.

Results

The shaft and annulus voids were successfully filled, restoring stability and reducing future maintenance risk.

The project was completed safely and efficiently, maintaining full rail operations throughout.

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