Introduction:
National Highway-367 (NH-367) is a critical cross-country route in Karnataka, carrying high volumes of commercial and commuter traffic every day. The Bagalkot Flyover in Hubli plays a vital role in ensuring smooth connectivity on this corridor. However, over time, settlement issues were observed at the bridge approach, posing risks to safety, ride quality, and long-term structural performance. URETEK India was engaged to deliver a fast, durable, and minimally disruptive solution using its proven ground improvement technology.
The Problem:
The bridge approach at the Bagalkot Flyover was experiencing noticeable sinking despite the road being topped with asphalt on at least three previous occasions. These surface-level repairs failed to address the root cause of the problem. Investigations revealed that voids and weak soil conditions had developed beneath the pavement layers near the bridge abutments, leading to ongoing settlement and uneven road levels.
Key Considerations
NH-367 is an extremely busy highway, and any repair work needed to be executed with minimal disruption to traffic flow. Lane closures had to be limited, safety maintained at all times, and the repair completed quickly without compromising quality. A permanent solution was required—one that would strengthen the underlying soil rather than provide another temporary surface fix.
Methodology Applied:
URETEK India implemented its specialised resin injection technique for ground stabilisation and lifting. Work was carried out by occupying one lane at a time, with traffic control measures in place to ensure uninterrupted vehicle movement.
High-performance expanding resin was injected into the voids beneath the road through small, strategically placed holes. As the resin expanded, it filled existing voids, compacted the surrounding soil, and applied controlled upward pressure—up to 40 tonnes per square metre—restoring the pavement to its original level. Ground strength tests (DCPs) confirmed significant improvement in soil bearing capacity following treatment.
Execution and Quality Control
URETEK’s trained site teams worked continuously, ensuring precision during injection and real-time monitoring of lift and soil response. The entire operation was conducted in accordance with international quality standards, with experienced specialists present on site throughout the process.
Results and Benefits:
Despite the presence of unexpectedly large voids beneath the road, the re-support work was successfully completed within just three days at both ends of the bridge. The road level was restored without undue interference to traffic, and no extended closures were required.
The treatment delivered:
- Permanent stabilisation of the bridge approach
- Elimination of voids and weak soil zones
- Improved ride quality and safety
- Minimal disruption to traffic on NH-367
- A long-lasting alternative to repeated asphalt overlays
Conclusion:
This project stands as a strong example of URETEK India’s ability to deliver fast, reliable, and permanent infrastructure solutions on critical highways. With over a decade of proven success in India, URETEK continues to support national road networks by addressing ground-related challenges efficiently and sustainably—keeping vital routes like NH-367 safe, stable, and operational.