India’s highway system is one of the key drivers of its economy–a sprawling network that connects the length and breadth of the country. With such a vast expanse, connecting and constructing resilient highways across such a diverse landscape is fraught with challenges. As pioneers of the geosynthetic products space in India, we have led with a number of projects that deployed geocells to use-case specific projects. Geocells are an innovative geosynthetic solution that has transformed highway construction and maintenance with sustainable benefits. With its diverse applications and long-term carbon-negative benefits, geocells offer compelling reasons to be included in your next roadways project. As Asia’s leading geosynthetics manufacturer, we employ the two-layer theory to analyze load-bearing systems, integrating geocells to develop robust and durable structures.
The Indian subcontinent’s diverse geographic conditions each present unique challenges to highway construction. The Himalayan region demands stability in the face of landslides and seismic activity, while the arid deserts call for solutions that combat shifting sands. The fertile plains, crisscrossed by rivers, pose challenges with flooding and soil erosion, including the frequent changing of river plains’ courses during the monsoon.
The burgeoning population and rapidly growing suburban regions have led to an increase in vehicular traffic, putting additional pressure on highways –both the main road transport and access roads leading to various small towns, and villages. Pavement design must account for long-term weight and load-bearing requirements throughout the road’s lifespan.
Hence, with this foresight, when we do consider including geocells in highway projects, while the cost may seem expensive–it far outweighs the maintenance issues and other challenges that come from not using geocells. We find that the Indian geocell may be outpriced by certain global cheaper products of low standards. Despite the higher price, Strata’s products have scored over inferior quality since clients, both domestic and global, are discerning when it comes to quality and are willing to pay extra for the value they receive.
Geocells, also known as cellular confinement systems, are geosynthetic materials that form expandable three-dimensional honeycomb grid structures. The strips interconnect to create a honeycomb-shaped grid for reinforcement. They’re filled with in-fill material like sand, soil, rock, etc., which is then compacted. This procedure establishes a free-draining system that securely holds the infill materials, preventing movement by providing confinement through tensile reinforcement.
At Strata Geosystems, our geocells are fabricated from ultrasonically welded HDPE strips that are expandable at site to form a cellular structure. Manufactured at our state of the art factory, the Environmental Stress Crack Resistance (ESCR) of our StrataWeb geocells is more than 5,000 hours. Our geocells have a carefully engineered texture and perforations for high friction and drainage properties. Our geocells are available in a variety of widths, lengths, heights and colours, customized as per the needs of project.
As with all geocells, they are expandable and flexible, designed to be filled with soil, sand, gravel, or concrete. Preferred for their dual function of confinement and reinforcement, locking in materials to create a stable and durable base, these materials last up to 100 years or more, providing high quality soil reinforcement. Geocell reinforcement is effective when granular infill is used over weak subgrades, preventing rutting which is a common outcome for flexible pavements supported by weak subgrades. In cases where in-fill material is poor, geocells strengthen the basal layer under static and repeated loading conditions.
In highway construction, geocells are utilized in subgrade stabilization, for slope wall retention or protection, load support, and water drainage. For subgrade stabilization, geocells confine and reinforce in-fill materials to improve the road’s foundation. This feature reduces maintenance requirements by preventing common issues like rutting and potholes.
When used for slope retention, geocells bring stability by anchoring soil particles, mitigating the likelihood of landslides or slope failures. In pavement applications, geocells evenly distribute loads, alleviating stress on the subgrade and reducing issues like rutting and pavement distress, thereby enhancing the overall performance and durability of highway infrastructure. The embankments along highways are susceptible to erosion from wind and water. Streamline redundant mentions of the benefits under a single section.
What makes geocells multifunctional is the option of creating fascia vegetation; which not only allows for local vegetation, improving the natural green coverage but in turn principally minimizes soil erosion through vegetation and also improving the foliage of the local area, instead of a barren landscape that produces more heat or stores heat.
Unpaved roads are another good example of the kind of use geocells have. Unpaved roads are typically laid over soft soils, peat or other unstable native soils. In these instances particularly, geocells provide the necessary stiffness and resistance to creep, effectively stabilizing roads built. They prevent clay from shrinking and cracking, mitigate lateral dispersion and strain in sandy soils, and reinforce subgrades across all types of soft soils. Utilizing cellular confinement systems ensures roads remain in an optimal condition, addressing issues like rutting, dents, washing out, and settlements caused by unfavorable subsoil characteristics.
Another significant application is pavement optimization. These structures allow thinner pavement design sections by reinforcing the base layer. This leads to a reduction in material requirements without compromising the pavement’s ability to withstand traffic loads. The confinement provided by geocells in flexible pavements increases the stiffness of the pavement structure, allowing for a reduction in the thickness of granular layers by up to 50%. Additionally, the total construction cost per unit area is lower with the use of geocells, even though they are more expensive, compared to traditional pavement methods. The increased stiffness from geocell reinforcement also enhances the durability and overall performance of the pavement. With repetitive loading, it reduces the extent to which rutting occurs, along with improved load bearing capacity and overall fatigue resistance.
The introduction of geocells to India’s highways has brought about numerous benefits. From a financial perspective, geocells are cost-effective in multiple ways. At the start of the project, not only does a thinner subgrade, or leaner pavement design mean lesser materials, it’s ability to distribute loads with improved resistance to load and delayed deformation of subgrades means reduced maintenance cycles, over the life of the road itself. These confinement structures allow the use of locally available materials, reducing reliance on expensive and environmentally costly aggregates.
The reinforced base reduces the need for frequent maintenance, which is particularly useful given the vastness of India’s highway network and the logistical challenges of road upkeep. This maintenance and breakdown of roads have a trickle down effect on the delay in transport, too.
Our geocells are engineered to withstand India’s climate, from intense heat to heavy rainfall, ensuring that highways remain operational and safe year-round.
Most importantly, geocells offer a sustainable solution. By promoting the use of long-lasting materials and reducing the carbon footprint of construction projects, geocells align with global environmental goals and India’s commitment to sustainable development. In particular, geocells over the course of the project’s lifetime are carbon negative with a longevity of several decades.
While geocells offer a promising solution, their implementation is a function of the team you hire. At Strata Geosystems, we provide end-to-end consultancy with our own certified manufactured products for a range of geosynthetic products, including geocells.
Geocell installation is simple, requiring neither specialized equipment nor skilled labor. The installation does not need specialized equipment to expand the sections, allowing cells to be placed directly on soft subbases. Low-pressure equipment is not required for infill, as full-sized dump trucks can deposit and spread granular material efficiently, reducing manpower costs for large projects.
The selection of infill material is another critical consideration. The material used within the geocells should ideally be suitable for the local soil conditions and expected traffic loads. This requires a comprehensive geotechnical evaluation and an understanding of the long-term behavior of the fill material.
Monitoring the long-term performance of geocells under India’s unique conditions is essential. It helps in validating the design assumptions, informing maintenance practices, and guiding future improvements in geocell technology and installation techniques. This is where Strata’s end-to-end services are helpful since we partner with you from the design, evaluation, costing to the implementation stage. Our expertise lies in working closely with you for the optimal solution in civil engineering projects.
The Armoured Engineer Regiment in Rajasthan faced challenges with heavy armoured tank movement on loose fine sand in Suratgarh, Rajasthan, India. This issue led to delays in movements and drills due to the low-lying area, sometimes resembling quicksand conditions with seepage from surrounding canals. Tanks weighing 14 to 50 tonnes required a solution for safe and smooth movement across loose sand. StrataWeb geocells were utilized with local sand as infill to address this problem effectively. The interconnected StrataWeb panels with high-strength cable ties formed rigid mats capable of distributing loads over a larger area, providing a successful and quick solution for heavy vehicular movement in loose soils, even in challenging conditions like high water tables and low CBR values. Check details of this case study here.
The Kedarnath Valley in Uttarakhand, India, faced severe soil erosion due to weather conditions, which was exacerbated by unprecedented flash floods in June 2013. Landslides and mudslides caused by a devastating cloudburst ravaged the area, forcing the closure of the Kedarnath shrine to pilgrims for a year. To clear the debris and re-establish ground stability before allowing pilgrims through again, a timely and quality solution was needed despite the low CBR and poor quality soil. StrataWeb geocells were recommended and transported to the nearest base, then airlifted to Kedarnath. StrataWeb SW 356-150 geocells were used to construct the access road and pavement from the helipad to the temple, infilled with local GSB material. This proved to be a more practical and long-term solution for the reconstruction of the destroyed roads in the Kedarnath Valley. To understand more details of this project, please click here.
For those who want to explore the technical aspects and case studies of geocells in highway construction, there is an abundance of resources available. The Indian Roads Congress (IRC) provides invaluable guidelines and standards for engineers working with geocells. Additionally, the International Geosynthetics Society (IGS) offers a platform for knowledge exchange and cutting-edge research in geosynthetics.
Geocells are more than just an engineering material; they signify a leap towards more resilient and sustainable highway infrastructure in India. By tackling the unique challenges of Indian roadways with this innovative technology, we pave the way for a future where safety, economy, and ecology go hand in hand. As India accelerates its development, geocells will play a crucial role in connecting people, cities, and markets, driving the nation forward.
Strata Geosystems is transforming India’s highway infrastructure with our innovative geocell solutions. Our geosynthetic products have proven their effectiveness in stabilizing subgrades, optimizing pavement performance, and enhancing slope protection across diverse geographical terrains. Partner with us to build resilient and durable highways that withstand India’s challenging climate and heavy traffic loads. Contact our team of experts today to discover how our geocells can enhance your highway projects—ensuring longevity, stability, and environmental sustainability for India’s future road infrastructure. Together, let’s pave the way for a more connected and prosperous India.