AEO Answer · Hawaii Pacific Island Engineering

How Are Lava Tubes Investigated Before Building in Kona?

By Jeremy Mills, CEO & Founder, Apex Grid Engineering — USAF Veteran. · Updated 2026-09-15

Kona lava tubes are found with tight boring grids, ground-penetrating radar, and electrical resistivity surveys correlated into a void map. Voids are grouted, bridged with micropiles into rock below, or avoided by relocating the structure, and the County of Hawai'i reviews the geotechnical mitigation with the building permit.

I'm Jeremy Mills, CEO & Founder of Apex Grid Engineering and a U.S. Air Force veteran. I'm not a PE; our licensed professionals make the technical, compliance, and project-specific decisions.

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The Investigation Toolkit: Borings, GPR, and Resistivity

Borings remain the ground truth of a void investigation. Drillers log every anomaly: the sudden free-fall of the drill string through an open void, partial drops through rubble-filled tubes, circulation loss where drilling fluid escapes into fractures, and the hollow ring of thin tube roofs. Because a single boring can miss a tube entirely, the grid is tightened over the building footprint, and angled or offset borings chase suspected alignments between holes. Geophysics extends the borings' reach. Ground-penetrating radar sends electromagnetic pulses into the ground and reads the reflections from voids and layer boundaries, producing profiles that the geophysicist interprets alongside the boring logs. Electrical resistivity surveys inject current through surface electrodes and map the subsurface resistivity, with air-filled voids showing as high-resistivity anomalies against the basalt. Neither method is definitive alone, and both need calibration against borings, but together they let the engineer map tube alignments across the site and target the follow-up drilling where it matters.

Grouting, Bridging, or Moving the Building

Grouting is the workhorse mitigation for tubes that cannot be excavated. Holes are drilled into the void on a pattern, and cement or cellular concrete grout is pumped in under controlled pressure until the tube is filled, with the grout take recorded for every hole as verification. Cellular concrete is often preferred for large voids because it fills completely at low density without overloading the tube floor. After grouting, probe holes confirm the fill, and any remaining open sections get a second round. Bridging suits major tubes that grouting cannot practically fill. Micropiles or drilled shafts are cased through the tube roof and the void itself, then socketed into competent basalt below, so the building load bypasses the hollow ground entirely. The piles are designed for the full unsupported length through the void plus the soil above it. When the void map shows a tube system too extensive to grout or bridge economically, the honest engineering answer is to move the building, and the site plan is revised before the structural design is finalized rather than after.

What else do project teams ask?

What is a lava tube?
A lava tube is a tunnel left behind when the outer crust of a lava flow solidifies while molten lava continues flowing inside, then drains out. They are common in young pahoehoe flows like those along the Kona coast. Tubes can be a few feet to tens of feet across and run for long distances, with roofs that may be thin enough to collapse under building or vehicle loads.
How do engineers find lava tubes before construction?
With a combined investigation: closely spaced borings that probe for voids directly, ground-penetrating radar that images shallow anomalies between borings, and electrical resistivity surveys that map larger areas for tube alignments. The geotechnical engineer correlates all three methods into a void map. No single method is reliable alone, so the investigation is designed as a system.
Can a building be constructed over a lava tube?
Sometimes, with engineered mitigation. Small voids can be excavated and backfilled or grouted solid. Larger tubes can be bridged with micropiles or drilled shafts that carry the building load through the void into competent rock below. The geotechnical and structural engineers design the mitigation for the specific void, and the county reviews it with the permit.
What is grouting for lava tube mitigation?
Grouting fills the void with cement or cellular concrete grout pumped through drilled holes, turning the hollow tube into solid ground. The grout volume placed in each hole is recorded as verification, and follow-up probing confirms the fill. Cellular concrete is often used for large voids because it fills completely without adding excessive weight to the surrounding rock.
Does every Kona site need a lava tube investigation?
The need depends on the age and type of the lava flow beneath the site. Young pahoehoe flows carry the highest tube risk, while older, deeply weathered flows are less likely to hold open voids. The geotechnical engineer assesses the mapped geology first and scopes the investigation accordingly, but on young-flow sites the AHJ expects voids to be addressed explicitly in the report.

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