Reinforced Cement Concrete Project in Chhatrapati Sambhaji Nagar, Maharashtra 

Case Study on HDPE Liner Application in Infrastructure Protection 

Introduction 

Rapid industrial and urban expansion across Maharashtra has led to a growing demand for durable reinforced cement concrete (RCC) infrastructure. From industrial utility corridors and drainage channels to containment structures and subgrade protection systems, RCC works increasingly require reliable lining and barrier systems to prevent seepage, erosion, and long-term structural degradation. 

This case study documents the application of Ocean HDPE Liner (300 Micron) supplied by Ocean Non Wovens for an RCC-related infrastructure project in Chhatrapati Sambhaji Nagar, Maharashtra. While the quantity involved was relatively compact in scale, the project reflects broader engineering challenges faced across India, particularly in regions with variable soil conditions, seasonal rainfall, and demanding service environments. 

Project Overview 

Project Name: Reinforced Cement Concrete Project 

Location: Chhatrapati Sambhaji Nagar, Maharashtra 

Product Supplied: Ocean HDPE Liner – 300 Micron 

Quantity Supplied: 2,857 SQM 

The project involved the use of HDPE liner as a protective and separation layer in RCC-related civil works. Such applications are common in drainage channels, utility corridors, subgrade protection beneath concrete slabs, and moisture barrier systems for industrial and infrastructure developments. 

Why HDPE Liners Matter in RCC Infrastructure 

Reinforced cement concrete structures are inherently strong, but they remain vulnerable to moisture ingress, chemical exposure, and subgrade instability over time. HDPE liners are used as a protective interface to address these vulnerabilities. 

Key functional roles of HDPE liners in RCC applications include: 

• Moisture Barrier: Prevents groundwater or surface water from migrating into concrete substructures, reducing the risk of reinforcement corrosion. 
• Seepage Control: Provides an impermeable layer under concrete channels, tanks, and drains. 
• Chemical Protection: Acts as a barrier between aggressive soils or industrial effluents and concrete surfaces. 
• Subgrade Separation: Reduces contamination between subgrade soil and RCC elements, helping maintain long-term structural performance. 

According to the Central Pollution Control Board (CPCB) guidelines on industrial wastewater containment, polymeric liners such as HDPE are widely recommended for containment and seepage control in lined channels and holding structures due to their low permeability and chemical resistance. 

Source: CPCB, “Guidelines for Management of Industrial Effluents and Wastewater”, Government of India. 

Role of Composite Mats in Related Civil Engineering Projects 

Although this project primarily used HDPE liners, geosynthetic cementitious composite mats (GCCM) are increasingly deployed in similar RCC-related infrastructure works across India. Composite mats function as concrete-on-a-roll systems that harden upon hydration, forming a thin, durable concrete layer. 

In related civil engineering contexts, composite mats are used for: 

• Lining drainage channels and canals to reduce erosion and seepage 
• Protecting slopes and embankments from surface runoff damage 
• Rapid lining of culverts and stormwater channels 
• Erosion protection beneath and around RCC structures 

Industry studies indicate that lined channels can reduce water losses due to seepage by 30 to 60 percent compared to unlined earthen channels, significantly improving hydraulic efficiency and structural longevity. 

Source: Food and Agriculture Organization (FAO), “Canal Lining: Principles and Practice”. 

The integration of HDPE liners beneath RCC or composite mat layers further enhances performance by providing a dual protection system against seepage and subgrade moisture intrusion. 

Broader Use of Geosynthetics in Infrastructure Applications 

Modern infrastructure projects rely on geosynthetics for multiple functional roles beyond simple lining. In RCC and allied civil works, geosynthetics support: 

1. Pavement Reinforcement 

Geogrids and geotextiles are used beneath concrete pavements to distribute loads, reduce reflective cracking, and improve service life. Research by the Indian Roads Congress highlights that geosynthetic reinforcement can extend pavement life by 20 to 40 percent when designed and installed correctly. 

Source: IRC SP:59, “Guidelines for Use of Geosynthetics in Road Pavements”. 

2. Soil Stabilisation 

Weak subgrades, especially clayey or expansive soils, benefit from geotextile separation layers that prevent intermixing of aggregates and fine soils, maintaining load-bearing capacity. 

3. Erosion Control 

Geosynthetic mats, composite mats, and geotextiles are widely used for slope protection, channel lining, and embankment stabilisation to control surface erosion during monsoon seasons. 

4. Drainage Improvement 

Geocomposites facilitate lateral drainage beneath RCC slabs, reducing hydrostatic pressure buildup and mitigating uplift risks in high water table areas. 

5. Environmental Protection 

HDPE liners are standard in containment structures, wastewater channels, and industrial utility corridors to prevent soil and groundwater contamination. 

Practical Site Challenges in Indian Conditions 

While this project was executed in Maharashtra, the challenges encountered are similar to those seen in regions like Guwahati and other high-rainfall or geotechnically complex zones across India. 

Variable Soil Conditions 

In many regions, subgrade soils range from silty clays to loose alluvial deposits. Such variability affects liner bedding preparation, as uneven settlement can lead to wrinkles, stress concentrations, and eventual liner fatigue. 

Monsoon Impact on Installation 

Seasonal rainfall significantly affects liner deployment schedules. Wet subgrades increase the risk of trapped moisture beneath liners, leading to poor adhesion with concrete overlays and potential uplift under hydrostatic pressure. Proper drainage layers and moisture control become critical during installation. 

Subgrade Preparation Limitations 

In constrained industrial or urban sites, achieving perfectly smooth subgrade profiles is challenging. Sharp stones, construction debris, or uneven compaction can compromise liner integrity if not carefully managed through protective cushioning layers such as non-woven geotextiles. 

Installation Complexities and Quality Control for HDPE Liners 

Installing HDPE liners beneath RCC structures demands more precision than often acknowledged in project planning. 

Surface Preparation 

The subgrade must be free from sharp objects, roots, and protrusions. Even minor surface irregularities can puncture thin liners under load. 

Seaming and Joint Integrity 

Although 300-micron liners are relatively thin, joint overlaps and sealing quality remain critical. Improper overlaps can become seepage pathways over time. Field inspection of seams, visual checks, and trial pulls are essential quality control measures. 

Anchorage and Edge Detailing 

Edges of liners must be properly anchored or terminated to prevent slippage during concrete pouring. Inadequate edge detailing often leads to liner displacement when wet concrete is placed. 

Protection During Concreting 

Direct contact with reinforcement bars, spacers, and construction equipment can damage liners. Temporary protective layers or careful sequencing of installation and concreting is required to avoid punctures. 

Long-Term Performance and Environmental Exposure 

HDPE liners are known for their durability, but long-term performance depends on environmental exposure and design detailing. 

• UV Resistance: Exposed liners degrade under prolonged ultraviolet exposure. Even temporary exposure during construction should be minimised. 
• Thermal Movement: HDPE expands and contracts with temperature fluctuations. Allowance for thermal movement during installation helps prevent wrinkling and stress concentrations. 
• Chemical Exposure: HDPE shows strong resistance to most industrial effluents, salts, and mild acids, making it suitable for utility corridors and drainage channels. 
• Mechanical Stress: Repeated loading from overlying RCC structures and traffic vibrations can induce fatigue over decades if cushioning layers are not provided. 

Laboratory ageing studies indicate that HDPE geomembranes can retain functional performance for several decades when protected from UV exposure and installed under controlled conditions. 

Source: Koerner, R.M., “Designing with Geosynthetics”, 6th Edition. 

Maintenance, Durability, and Lifecycle Benefits 

One of the less discussed advantages of HDPE liners in RCC infrastructure is lifecycle cost optimisation. While liners add to initial project costs, they significantly reduce long-term maintenance expenses by: 

• Minimising water ingress into concrete, reducing reinforcement corrosion 
• Preventing subgrade weakening due to seepage 
• Reducing frequency of repairs in lined channels and utility corridors 
• Extending service life of RCC structures in moisture-prone environments 

Lifecycle assessments of lined versus unlined drainage systems show that maintenance costs can be reduced by 25 to 40 percent over a 20-year period when effective lining systems are used. 

Source: FAO Irrigation and Drainage Papers, “Canal Operation and Maintenance”. 

Conclusion 

The Reinforced Cement Concrete project in Chhatrapati Sambhaji Nagar demonstrates how even relatively thin HDPE liners play a critical role in protecting RCC infrastructure from moisture ingress, subgrade interaction, and long-term deterioration. Beyond individual projects, the integration of geosynthetics, including HDPE liners and composite mats, is steadily reshaping how infrastructure is designed for durability, environmental safety, and lifecycle efficiency in India. 

Final Note 

Ocean Non Wovens brings deep technical understanding, manufacturing capability, and on-ground execution experience to infrastructure projects across India. From supplying precision-engineered HDPE liners to supporting large-scale geosynthetics deployment in complex site conditions, Ocean Non Wovens is a trusted partner for contractors, consultants, and project owners seeking reliable, high-performance geosynthetic solutions for long-term infrastructure resilience.