Case Study: Application of Non Woven Geotextiles in Industrial Infrastructure

• Project: Reliance Project
• Location: Chandauli, Uttar Pradesh
• Product Supplied: Ocean Non Woven Geotextile 3 MM (Polyester)
• Quantity: 16,184 SQM

Introduction

Large industrial and infrastructure projects demand ground improvement solutions that go beyond conventional civil engineering methods. Weak subgrades, fluctuating groundwater levels, and heavy operational loads can significantly affect pavement life, drainage performance, and long-term stability. Geosynthetics, particularly geotextiles and geogrids, have become integral to modern infrastructure development due to their ability to enhance soil performance, improve load distribution, and extend the service life of pavements and foundations.

The Reliance project in Chandauli, Uttar Pradesh, involved infrastructure development that required stable ground conditions, controlled drainage, and long-term durability under industrial traffic loads. Ocean Non Wovens supplied 16,184 square metres of Non Woven Geotextile (3 mm, polyester) for separation, filtration, and drainage applications across the project footprint. This case study explores how geotextiles and geogrids contribute to infrastructure performance in such projects, along with practical engineering insights often overlooked in project documentation.

Project Context and Ground Conditions

Chandauli lies in eastern Uttar Pradesh, where soil conditions typically comprise alluvial deposits with varying proportions of silt, clay, and fine sand. Such soils can exhibit moderate bearing capacity but are often sensitive to moisture variations. During monsoon months, increased water ingress can lead to reduced shear strength, subgrade pumping, and localized settlement under heavy traffic or equipment loads.

Industrial facilities, logistics yards, and internal access roads within large projects like this are subjected to repetitive heavy axle loads. Without proper separation and drainage layers, fine soil particles migrate into granular base courses, leading to clogging, loss of load-bearing capacity, and premature pavement distress. According to IRC:SP:59 and IRC:37 guidelines for pavement design in India, subgrade performance and drainage play a decisive role in determining pavement life, particularly in regions with high rainfall variability.

Role of Non Woven Geotextiles in the Reliance Project

The Ocean Non Woven Geotextile (3 mm polyester) was primarily used to perform three critical functions:

1. Separation

Non woven geotextiles act as a physical barrier between the subgrade and granular layers. This prevents fine soil particles from migrating upward into the base and sub-base layers. Studies published by the Federal Highway Administration (FHWA) indicate that effective separation using geotextiles can significantly reduce rutting and deformation in pavements constructed over weak or silty subgrades.

2. Filtration and Drainage

Polyester non woven geotextiles allow controlled water flow while retaining soil particles. This filtration function is particularly important in regions where seasonal rainfall leads to temporary saturation of the subgrade. Proper filtration ensures that drainage layers remain unclogged, maintaining permeability and preventing pore water pressure buildup, which can otherwise weaken the pavement structure.

3. Protection of Underlying Layers

In areas where geosynthetic layers are combined with geomembranes or granular drainage systems, non woven geotextiles provide cushioning and protection against puncture or mechanical damage during construction and service life. This protective role contributes directly to the durability of the overall system.

Application of Geogrids in Similar Industrial and Infrastructure Projects

While geotextiles were supplied for this project, geogrids play a complementary and often critical role in industrial and heavy-duty pavement applications. Geogrids are primarily used for reinforcement and load distribution. Their functions include:

Pavement Reinforcement

Geogrids placed at the interface of subgrade and base course improve load transfer by interlocking with aggregate particles. Research by the Indian Roads Congress and international bodies such as the Transportation Research Board (TRB) shows that geogrid-reinforced pavements can achieve equivalent performance with reduced base thickness, leading to material and cost savings over the project lifecycle.

Soil Stabilization

In areas with variable subgrade strength, geogrids help distribute loads over a wider area, reducing localized shear failure. This is particularly relevant for industrial yards, container stacking areas, and heavy equipment movement zones.

Erosion Control and Slope Stability

Geogrids, when combined with geotextiles, are widely used in embankments, slope reinforcement, and erosion-prone zones. They improve slope stability and resist tensile forces generated by soil movement, especially during intense rainfall events.

Practical Site Challenges Often Overlooked

Subgrade Variability

Even within a single project site, soil properties can vary significantly. Pockets of softer soil may exist due to past land use, fill material, or natural depositional patterns. Blanket design assumptions without localized investigation can lead to uneven settlement. The use of geotextiles and geogrids helps mitigate such variability, but proper geotechnical mapping remains critical.

Monsoon Impact and Construction Windows

Construction schedules in North India are frequently disrupted by monsoon rains. Wet subgrades are prone to rutting during construction traffic, which can compromise the performance of installed geosynthetics. Temporary working platforms, proper sequencing of layer placement, and moisture control measures are essential to protect the integrity of geotextile layers during installation.

Installation and Quality Control Complexities

Geosynthetics are often perceived as “easy to install,” but field performance depends heavily on installation quality. Wrinkles, overlaps that do not meet design specifications, damage from equipment, and contamination with fine soils can reduce effectiveness. International guidelines such as ISO 10318 and ASTM D4439 emphasise strict quality control during handling, placement, and covering of geosynthetics. On-site supervision and training of installation crews are practical necessities, not optional add-ons.

Long-Term Performance and Lifecycle Considerations

Durability in Heavy Traffic Conditions

Polyester non woven geotextiles exhibit good tensile strength and resistance to creep, making them suitable for long-term infrastructure applications. Long-term studies indicate that geosynthetics designed for civil engineering use can retain functional performance for several decades when properly selected and installed. Factors such as UV exposure during storage, chemical compatibility with soil and groundwater, and mechanical damage during construction must be controlled to ensure expected service life.

Maintenance Implications

One of the less-discussed advantages of geosynthetics is their impact on maintenance cycles. Improved separation and drainage reduce the frequency of pavement rehabilitation caused by pumping, rutting, and base contamination. While geosynthetics themselves are not directly serviceable post-installation, their presence lowers long-term maintenance costs and extends the interval between major pavement interventions.

Environmental and Resource Efficiency

By improving structural performance, geosynthetics enable thinner pavement sections and reduced consumption of aggregates. The World Bank and FHWA have highlighted geosynthetics as a resource-efficient solution that lowers material extraction, transportation emissions, and overall project carbon footprint, particularly in large-scale infrastructure developments.

Broader Applications of Geosynthetics in Infrastructure

Beyond industrial projects, geotextiles and geogrids are widely used in:

• Highway and rural road construction for pavement reinforcement and separation
• Railway track beds for ballast stabilization and drainage
• Landfills and waste containment systems for filtration, protection, and environmental safeguarding
• Riverbank protection, canals, and coastal works for erosion control
• Retaining walls and reinforced soil structures for slope stability

These applications reflect the versatility of geosynthetics in addressing geotechnical and environmental challenges across diverse terrains and loading conditions.

Conclusion

The Reliance project in Chandauli demonstrates how non woven geotextiles contribute to stable, durable infrastructure when integrated thoughtfully into pavement and ground improvement systems. The performance of such systems depends not only on material selection but also on site-specific understanding, disciplined installation practices, and long-term design thinking. As infrastructure projects in India scale in size and complexity, the role of geosynthetics will continue to expand from being an “optional add-on” to a core component of resilient engineering design.

Ocean Non Wovens brings deep technical expertise and execution capability to large-scale infrastructure projects across India. With proven manufacturing standards, project-specific solution design, and on-ground support for installation and quality control, the company has established itself as a reliable partner for complex geosynthetics applications. From industrial developments to highways and environmental protection works, Ocean Non Wovens consistently delivers engineered geosynthetic solutions that enhance performance, extend asset life, and support the long-term sustainability of critical infrastructure.