Challenge
Voids were identified beneath infrastructure at Tunstall Reservoir, posing risks to structural stability and long‑term asset performance in a sensitive water management environment.
Solution
Geobear delivered precision geopolymer injection to fill subsurface voids, stabilise surrounding ground and restore uniform support with minimal environmental disturbance.
Subsurface instability mitigated
Structural integrity maintained
Minimal disruption to operations
The client had a requirement at Tunstall Reservoir to fill a disused adit tunnel to prevent potential structural issues and ensure the long-term stability of the reservoir infrastructure.
Project Scope and Objectives
Location: Tunstall Reservoir, Northumberland, UK.
Objective: Fill a disused adit tunnel measuring approximately 120 meters in length with a 2m x 2m cross-section to prevent structural instability.
Methodology: Utilise expansive geopolymer injected through pre-formed holes.
Volume: Up to 480m³.
Duration: Estimated 2 weeks.
Site Accessibility: Limited space and the need to reduce the reservoir water level to prevent inflow into the adit. This was managed by strategic placement of the Geobear injection unit and coordination with the reservoir management team.
Rough-hewn Walls: The old Victorian adit’s rough-hewn walls presented additional challenges for the injection process. These were mitigated through careful planning and monitoring.
Obstructions: Potential obstructions in the adit were accounted for, with provisions for additional drilling and adjustments in the injection process as necessary.
Weather Conditions: Adverse weather conditions could delay the project. Contingency plans included flexible scheduling and protective measures for equipment and personnel.
Design drawing:

Project Planning and Execution
Initial Assessment and Planning:
Comprehensive site surveys were conducted to understand the existing conditions and constraints.
A detailed project plan, including a Construction Phase Plan (CPP) and Risk Assessment and Method Statement (RAMS), was prepared to ensure compliance with health, safety, and environmental standards.
Site Preparation:
Establishment of safe working areas with adequate access for Geobear’s mobile injection units adjacent to the site.
The tunnel, an old Victorian adit with rough-hewn walls and difficult access, required careful planning to navigate its challenging conditions.
Injection Process:
A 12mm diameter injection tube was manually inserted into the void through pre-formed holes.
The Geobear self-contained injection unit, including the geopolymer material, pumped the multi-component liquid geopolymer material to the injection locations
The geopolymer expanded up to 30 times its volume, filling the void and ensuring structural integrity.

The Tunstall Reservoir void fill project was successfully completed within the two-week timeframe.
The use of Geobear’s geopolymer injection technology provided a robust solution to fill the disused adit, ensuring the structural stability of the reservoir.
Get in touch with our expert team today and discover how Geobear can extend the life of your critical infrastructure assets.