NWR Doubling Project KTWS–NNL: Reinforcing Railway Infrastructure with Geocell Technology

Project Overview

The doubling of the railway line between North Western Railway (NWR)’s Kathuwas (KTWS) and Narnaul (NNL) in Mahendragarh district, Haryana — the “NWR Doubling Project KTWS–NNL” — represents a strategic upgrade aimed at enhancing capacity, reducing congestion, and improving the efficiency of both freight and passenger traffic. As part of this project, our team at Ocean Non Wovens had the opportunity to supply and install geosynthetic reinforcement material to ensure the long-term stability and performance of the railway embankment and track substructure.

For this specific assignment, we supplied and installed 380 SQM of Ocean Geocell 356×150 mm. The use of geocell technology in railway doubling projects like KTWS–NNL is increasingly common — and with good reason.

Why Geocell Was the Right Choice for KTWS–NNL

Railway doubling and track reinforcement projects often face several geotechnical challenges, especially when the subsoil exhibits poor bearing capacity, variable composition (clays, silts, sandy loam), or is prone to settlement and waterlogging. Traditional approaches such as thick granular sub-bases, deep soil replacement, or stone column techniques are often expensive, time-consuming, and not always sustainable.

Geocell-based solutions, by contrast, offer a compelling alternative. According to standard geocell functionality guidelines used in railway embankments, a geocell’s three-dimensional honeycomb structure confines infill material, improving shear strength, bearing capacity, and reducing deformation under load. 

Specifically for railway track applications, geocells help distribute dynamic loads from passing trains over a wider area, reduce vertical stress on weak subgrades, and enhance long-term stability under cyclic loading conditions. 

In the context of the KTWS–NNL stretch — where soil variability, seasonal weather shifts, and the demands of increased rail traffic posed significant risks — geocell was the optimal choice.

About Ocean Geocell 356×150 mm

The product used — Ocean Geocell 356×150 mm — is a high-density polyethylene (HDPE) cellular confinement system designed for sub-base and subgrade reinforcement applications. The cell dimensions (356 mm width, 150 mm height) provide a sturdy, stable cellular matrix that — when properly infilled and compacted — offers excellent load distribution, confinement, and long-term durability.

While many project reports focus solely on much larger geocell sizes or use broad-brush descriptions, selecting a 356×150 mm configuration for this segment allowed us to:

• Use locally available infill material (sandy loam, granular soil), minimizing the need for imported aggregates, thus reducing cost.
• Keep the geocell profile relatively slim, which helped in maintaining required embankment geometry without excessive buildup — a key consideration for a track-doubling project where vertical clearance and embankment levels must conform to strict railway design norms.
• Achieve high soil confinement and load distribution without overspecifying the section — striking a balance between performance and cost.

Engineering & Installation: What Went Into the Deployment

The deployment of Ocean Geocell 356×150 mm across 380 SQM at KTWS–NNL involved careful planning and execution to ensure performance matched expectations. Key steps included:

1. Subgrade Preparation: The native soil was first graded and compacted to provide a stable base. Any loose or soft pockets were identified and densified, ensuring uniform bearing conditions.
2. Geocell Deployment: The geocell sheets were laid out, expanded on site, and pinned into place — ensuring full contact with the prepared subgrade.
3. Infill with Locally Available Material: Instead of importing granular aggregate, locally available soils (silty loam, sandy loam, or mixed fill) were used to infill the geocells. This not only reduced cost, but leveraged the confinement effect of the geocell to make otherwise marginal fills serviceable.
4. Compaction in Layers: The infill was compacted in layers using vibratory compactors — ensuring the infill achieved desired density. Geocell’s confinement ensures compaction remains stable over time even under cyclic loading. 
5. Final Capping and Integration with Track Structure: Once compacted, the reinforced sub-base was capped as per railway embankment design — providing a stable, durable platform for ballast and track substructure.

This approach helped reduce dependency on high-grade aggregate, sped up construction, and maintained embankment integrity even under heavy axle loads.

Unique Insights: What Most Case Studies Don’t Cover

Many publicly available case studies or project reports highlight only the supply and installation volumes. In our experience — especially on KTWS–NNL — a few more nuanced observations stand out.

Subgrade Variability and Seasonal Stress

Mahendragarh’s soil profile varied significantly along the KTWS–NNL stretch — from sandy loam to silty clay, with patches of loess-like, compressible subsoil. During summer months, high temperatures can induce soil shrinkage and cracking; during monsoon, moisture infiltration can lead to softening and settlement. By using geocell confinement, we effectively neutralized both extremes: the infill remained locked within the cells, preventing lateral migration, collapse, or uneven settling.

Use of Marginal Infill Material — Sustainability + Cost Efficiency

Instead of relying on premium-quality aggregates, we used locally available fill. The geocell’s cellular confinement turned this marginal material into a load-bearing composite layer — a solution that saved on material costs, reduced transport-related carbon emissions, and accelerated project timelines.

Drainage and Water Management Considerations

On some sections where waterlogging risk was higher (due to nearby agricultural runoff or shallow groundwater), we ensured proper subgrade drainage before geocell placement. While geocell itself does not guarantee drainage, when integrated with a well-compacted subgrade and proper capping, it helps maintain sub-base stability even in presence of occasional moisture — a detail often skipped in many case histories.

Longevity and Maintenance Implications

Conventional granular sub-bases often suffer from ballast contamination, lateral spreading, or settlement over repeated train cycles — leading to high maintenance costs. By contrast, a geocell-reinforced sub-base provides a “rigid mattress” effect, distributing loads evenly and resisting deformation over long-term use. Professional studies have shown that geocell confinement in railway ballast/sub-base can significantly reduce vertical and lateral deformations under cyclic loading. 

Given these factors, the actual lifecycle cost of the line — factoring reduced maintenance, enhanced stability, and lower material needs — becomes more favorable than conventional construction.

Impact of the Geocell Implementation on KTWS–NNL

Even though the quantity used (380 SQM) was modest relative to the total track length, deploying Ocean Geocell 356×150 mm in critical sub-base zones delivered outsized benefits:

• Enhanced Subgrade Bearing Capacity — The reinforced sections now support heavy axle loads with minimized risk of differential settlement or subgrade punching under load.
• Optimized Use of Resources — Use of locally available fill material meant lower aggregation of imported material, reduced transportation, and minimized environmental footprint.
• Faster Implementation — The geocell-based reinforcement saved time compared to conventional deep granular fill or soil replacement, helping keep the doubling project on schedule.
• Long-Term Stability — The reinforced sub-base offers a stable foundation less prone to deformation, thereby promising longer maintenance intervals and lower life-cycle costs.
• Sustainability & Cost Efficiency — Reduced dependency on high-grade aggregates conserves natural resources and lowers total project cost.

In broader terms, this project demonstrates how carefully selected geosynthetics can play a decisive role even in a large-scale infrastructure upgrade — not just as “supporting materials,” but as central to ensuring structural resilience and sustainability.

Conclusion: Rethinking Railway Infrastructure — Geosynthetics as a Core Solution

The NWR Doubling Project KTWS–NNL in Mahendragarh stands as a testament to how modern geosynthetic engineering — even with moderate quantities of material — can significantly enhance railway substructure performance, sustainability, and cost-effectiveness. Using Ocean Geocell 356×150 mm across critical zones allowed the project to address soil variability, seasonal stresses, and long-term loading demands, all while optimizing resources and construction timelines.

At Ocean Non Wovens, we believe that geosynthetics are not just optional add-ons — they are foundational enablers for modern, resilient infrastructure. Whether your project involves railways, highways, landfills, slopes, or water containment, our solutions are engineered for performance, longevity, and sustainability.

If you are planning a future infrastructure project and want a partner who understands both geotechnical challenges and engineering economics, reach out to Ocean Non Wovens. We offer tailored geocell, geotextile, geomembrane, and related geosynthetic solutions — backed by project-proven reliability, technical expertise, and a commitment to sustainable development.

Let’s build India’s infrastructure stronger, smarter — together.