Strengthening Railway Infrastructure with Geocell Technology: Ocean Non Wovens’ Role in the NWR Doubling Project, KTWS–NNL

Project overview

North Western Railway (NWR) is doubling the track between Kathuwas (KTWS) and Narnaul (NNL) in southern Haryana, running to Narnaul in Mahendragarh district. Doubling adds line capacity, cuts delays and lets freight and passenger trains run more safely and at better speeds.

For this project Ocean Non Wovens supplied and installed 10,000 square meters of Geocell 660*75 for ground reinforcement and soil stabilization.

Why the project needed geocell

On the KTWS–NNL section, subgrade instability, soil erosion and differential settlement were the main concerns, given the alluvial and windblown sandy soils of the area and their limited bearing capacity. Compacted granular fills or stone columns are the traditional answers, but both are costly and slow. The project engineers chose geocell-based reinforcement instead, a method widely used in transport infrastructure.

Product deployed: Geocell 660*75

Geocell 660*75 is a three-dimensional honeycomb made from high-density polyethylene (HDPE) strips welded together at intervals. In the usual geocell designation, 660 mm is the spacing between welds, which sets the size of the expanded cell, and 75 mm is the cell depth. The grade was selected for its balance of confinement, drainage and load distribution.

Key features of Geocell 660*75

• Cell Depth: 75 mm, a shallow cell suited to confining cover soil and to moderate load support.
• Weld Spacing: 660 mm, giving large cells that cover more area per panel.
• Material: UV-resistant HDPE for long life and minimal degradation.
• Load Distribution: spreads vertical loads laterally, reducing stress on the subgrade.
• Erosion Resistance: holds soil in place under vibration or flowing water.

According to Ocean, the product was made to Indian Railways specifications and quality-tested before deployment.

Installation

The 10,000 SQM of Ocean Geocell 660*75 was installed in stages to a tight programme:

1. Subgrade Preparation: the native soil was graded and compacted to a level foundation.
2. Placement of Geocells: the geocells were expanded on site and held with reinforced polymeric or metal stakes.
3. Infill Material: locally available granular material filled the cells, reducing cost.
4. Layer Compaction: each layer was compacted with vibratory rollers to the specified Proctor density.
5. Top Layer Finishing: the final layer was capped with a ballast bed to the track design.

The result is a firm platform that carries the dynamic loads of passenger trains and heavy freight.

Why geocell suits rail infrastructure

• Less ballast fouling: a confined sub-base pumps less fine material up into the ballast, so ballast cleaning is needed less often.
• Faster installation: panels expand and fill quickly compared with deep soil replacement or stone columns.
• Lower carbon footprint: local infill avoids the emissions of hauling engineered fill.
• Drainage: perforated geocell walls let water move between cells, which helps limit waterlogging in embankments.

Project outcomes

• Trackbed stabilization over 10,000 SQM.
• Reduced differential settlement, for safety and longevity.
• Faster construction, keeping the doubling project on schedule.
• Lower cost than traditional reinforcement methods.
• Less long-term maintenance.

About Ocean Non Wovens

Ocean Non Wovens has over a decade of experience manufacturing and supplying HDPE geocells, geotextiles, geomembranes, geogrids and other geosynthetics for infrastructure. For highways, railways, landfills or erosion control, the team handles delivery, technical support and project-specific customization. Contact us to discuss your site.