Case Study: Application of GCCM in Industrial Infrastructure

• Project: Reliance Project
• Location: Jogwad, Gujarat
• Product Used: Ocean Geosynthetic Cementitious Composite Mat (GCCM) 12 mm
• Quantity Supplied: 900 sqm

Introduction

Large industrial projects demand infrastructure solutions that combine speed of execution, structural reliability, and long-term durability. As industrial corridors expand across India, project owners are increasingly turning to advanced geosynthetic materials to address challenges such as erosion control, surface protection, slope stabilization, and protection of drainage channels and subgrades.

The Reliance project at Jogwad, Gujarat, presented a typical industrial site scenario where conventional concrete lining and stone pitching methods were both time-consuming and logistically demanding. To address site-specific requirements, Geosynthetic Cementitious Composite Mat (GCCM) was adopted as a modern alternative, offering faster installation, consistent performance, and controlled quality in challenging field conditions.

Project Context and Site Conditions

Jogwad, located in Gujarat, experiences semi-arid climatic conditions with pronounced seasonal variability. While much of the year remains dry, short-duration but high-intensity rainfall during monsoon periods can create rapid surface runoff, erosion of exposed soil faces, and localized scouring around drainage paths and infrastructure foundations.

Industrial sites in such regions typically face the following ground and environmental challenges:

• Subgrade variability: Mixed soil profiles ranging from sandy silts to clayey pockets, leading to uneven bearing capacity.
• Surface erosion risk: Sudden rainfall events generate high-velocity runoff, which can erode exposed slopes and embankments.
• Dust and surface degradation: Dry seasons result in loose surface materials, affecting stability and maintenance.
• Construction time pressure: Industrial projects often operate under strict timelines, making prolonged curing periods of traditional concrete impractical.

According to the Indian Roads Congress (IRC) and Central Road Research Institute (CRRI), uncontrolled surface erosion and poor drainage are among the leading contributors to premature deterioration of industrial pavements and embankments in infrastructure projects. Studies by FHWA and CIRIA further indicate that erosion-related failures account for a significant share of slope and channel maintenance costs globally.

Role of GCCM in the Reliance Project

Geosynthetic Cementitious Composite Mat (GCCM) is a factory-manufactured composite consisting of a dry concrete layer encapsulated within geotextiles. When hydrated on site, the mat hardens to form a durable, low-permeability concrete layer that conforms closely to the underlying surface.

At the Jogwad project, Ocean GCCM 12 mm was used primarily for:

• Surface protection of drainage channels and run-off paths
• Erosion control on exposed soil surfaces
• Protective lining in industrial utility corridors

The selection of GCCM offered multiple technical advantages over traditional concrete lining:

• Rapid installation: GCCM can be deployed up to 10 times faster than conventional concrete in certain applications, as noted in technical guidance by CIRIA (UK).
• Reduced logistics: No need for on-site batching, shuttering, or heavy concrete placement equipment.
• Consistent thickness and performance: Factory-controlled material properties reduce variability often seen in field-mixed concrete.
• Improved conformity: The mat closely follows irregular subgrade profiles, minimizing voids and undercutting risks.

Broader Role of Geosynthetics in Industrial and Infrastructure Projects

Beyond GCCM, geosynthetics play a critical role across multiple infrastructure functions:

1. Pavement Reinforcement Geogrids and geotextiles improve load distribution and reduce reflective cracking in industrial pavements. Research by FHWA suggests that geosynthetic-reinforced pavements can extend service life by 30 to 50 percent when properly designed and installed.
2. Soil Stabilization Geotextiles and geogrids enhance the shear strength of weak subgrades, particularly in areas with variable soil conditions. This reduces the need for over-excavation and replacement with granular fill.
3. Erosion Control Products such as GCCM, erosion control mats, and turf reinforcement mats protect exposed surfaces from rainfall impact and runoff, particularly during early construction stages before vegetation establishes.
4. Drainage Improvement Geocomposites facilitate controlled drainage, preventing pore water pressure build-up and reducing the risk of subgrade weakening. Proper drainage design is consistently highlighted by IRC and BIS codes as critical for pavement longevity.
5. Environmental Protection Geosynthetics are widely used in containment systems, channels, and industrial water management structures to limit soil erosion, prevent sediment transport, and reduce contamination risks.

Practical Challenges and Field Realities

While geosynthetics offer strong technical benefits, their performance depends heavily on site execution, an aspect not often discussed openly.

1. Subgrade Preparation Challenges

Even minor undulations or soft pockets in the subgrade can affect GCCM performance. In industrial sites, uneven compaction and residual construction debris can lead to localised voids beneath the mat, increasing the risk of cracking over time. Proper trimming, compaction, and removal of sharp protrusions are essential.

2. Installation and Quality Control Complexities

Although GCCM installation is faster than conventional concrete, it requires disciplined quality control:

• Correct overlap and joint detailing
• Proper anchoring at terminations
• Uniform hydration to ensure full cementitious activation
• Protection during the initial curing period from premature drying or heavy foot traffic

International guidance from CIRIA and ASTM standards emphasize that inconsistent hydration and poor anchoring are among the most common causes of early performance issues in GCCM installations.

3. Long-Term Performance Considerations

Composite mats are designed to perform under varied environmental conditions, but long-term durability depends on:

• UV exposure resistance of the outer geotextile layers
• Resistance to chemical exposure in industrial effluent channels
• Mechanical resistance to abrasion in high-flow zones

Laboratory studies published in geosynthetics journals indicate that properly specified GCCM can maintain structural integrity for decades when protected from extreme mechanical damage and designed within hydraulic limits.

4. Maintenance and Lifecycle Benefits

Unlike conventional concrete linings that may require patch repairs, re-pointing, and crack sealing, GCCM-lined surfaces typically demand lower routine maintenance. Reduced vegetation growth on lined channels and controlled erosion significantly cut recurring maintenance costs. Over a 20 to 30-year lifecycle, this translates into measurable operational savings for industrial asset owners.

Conclusion

The application of Ocean GCCM 12 mm at the Reliance project in Jogwad, Gujarat, demonstrates how advanced geosynthetic solutions can address practical site challenges while delivering long-term infrastructure performance. By combining erosion control, surface protection, and construction efficiency in a single system, composite mats offer a technically robust alternative to conventional lining methods for industrial and civil engineering projects

Ocean Non Wovens brings together manufacturing capability, technical understanding, and on-ground project experience to deliver geosynthetic solutions that perform in real-world Indian site conditions. From product selection to execution support, our team works closely with project stakeholders to ensure reliability, quality, and long-term value. For large-scale infrastructure and industrial developments across India, Ocean Non Wovens remains a trusted partner for engineered geosynthetics that stand up to demanding environments and timelines.