Case Study: Pond Lining Project in Surat, Gujarat

Product Used: Ocean HDPE Liner 1000 Micron

Quantity: 18,000 SQM

Location: Surat, Gujarat

Introduction

Water conservation and efficient containment are critical concerns in infrastructure and agricultural projects across India. Traditional methods of lining ponds using clay or concrete often result in significant seepage, higher maintenance costs, and shorter lifespans. In response to these challenges, geosynthetic solutions like high-density polyethylene (HDPE) liners are becoming the standard for modern pond lining projects. Here we present a detailed case study of a successful Pond Lining project in Surat, Gujarat, where Ocean Non Wovens supplied and installed 18,000 square meters of Ocean HDPE Liner 1000 Micron to achieve superior performance and durability.

Project Overview and Client Needs

The project in Surat involved the construction of a large agricultural and water retention pond intended to store monsoon runoff and irrigation water throughout the dry season. The client’s key requirements were:

• Reliable water retention with minimal seepage
• Long service life
• Resistance to harsh environmental conditions
• Cost-effective solution compared to traditional lining materials

Given these requirements, Ocean Non Wovens recommended a high-performance geosynthetic solution using an HDPE liner with a thickness of 1000 micron. This thickness is suitable for large bodies of water and ensures robust puncture resistance, long term impermeability, and durability. Industry data shows that HDPE liners with thickness in the range of 1 mm (1000 micron) are commonly selected for larger ponds and reservoirs to handle higher hydrostatic pressures and environmental stress. 

Why HDPE for Pond Lining

High-density polyethylene (HDPE) pond liners are engineered specifically to create a watertight barrier between water and soil. They offer several advantages over traditional lining methods:

• Impermeability: HDPE geo-membranes have extremely low permeability, typically with a coefficient around 1×10⁻¹⁷ cm/s, which ensures almost complete water retention. 
• Durability: HDPE liners are chemically inert, resistant to acids and alkalis, and withstand UV exposure and weathering for decades, often offering a service life of 20 to 50 years. 
• Chemical and Biological Resistance: Because of their composition and stabilisers, these liners resist degradation from organic matter and chemicals found in soil and water, which is especially important in agricultural applications. 
• Flexibility and Conformance: Despite their strength, HDPE liners remain sufficiently flexible to conform to irregular pond contours, an advantage during installation on uneven terrain. 

Industry reviews have also highlighted that HDPE liners provide a more cost-effective solution than clay or concrete by significantly reducing seepage losses and lowering maintenance needs over time. 

Technical Highlights of Ocean HDPE Liner 1000 Micron

The Ocean HDPE Liner 1000 Micron used in this project was selected to meet the specific challenges of a large pond in Surat:

• Thickness: 1000 micron (1 mm), providing enhanced puncture resistance and longer life expectancy compared to thinner alternatives. 
• Material Quality: Manufactured from high-grade polyethylene resin with additives for UV stability and enhanced weather resistance. 
• Water Retention: Capable of providing nearly complete containment with minimal seepage, essential for conserving irrigation water during dry spells. 

Installation Considerations

Successful pond lining requires thoughtful preparation and execution. The base of the excavation must be cleared of sharp objects and debris. In many pond liner installations, non-woven geotextiles are placed beneath the geomembrane to provide puncture protection and improve performance, although the exact underlayment used varies based on site conditions. 

Proper overlapping and thermal fusion welding of panels are critical to ensuring water-tight seams. Because of the large area involved in this project, panels were methodically overlapped and fusion welded to achieve a continuous impermeable barrier.

Challenges and How They Were Overcome

Soil Condition Variability: Surat’s alluvial soil posed a risk of fine particles migrating under a less robust liner, potentially leading to seepage. The 1000 micron thickness provided significant resistance against such migration, ensuring greater system reliability.

Water Pressure and Depth: Thicker liners are recommended where higher hydrostatic pressures are anticipated, as thinner liners can be vulnerable to puncture or stress cracking. Choosing a 1000 micron liner mitigated this risk and provided assurance against long-term deformation. 

Environmental Exposure: The selected liner’s UV resistance and chemical inertia ensured resistance to sunlight and agricultural runoff chemicals, crucial for long-term performance. 

Results and Performance Outcomes

Post-installation monitoring showed excellent performance. The pond retained water effectively with negligible seepage, helping conserve stored water over critical dry months. The client reported that water levels remained stable weeks after filling, validating the impermeability and durability of the HDPE liner system.

Compared to expected outcomes with clay or concrete, the HDPE system reduced potential seepage loss by more than half and offered an overall maintenance cost advantage over the projected life of the pond.

What Most Companies Don’t Talk About

Many pond lining case studies focus on upfront material costs or basic performance metrics. What is often overlooked includes:

• Long-term life cycle savings: HDPE liners like the one used here significantly reduce maintenance costs and the frequency of repair compared to traditional materials.
• Environmental resilience: In regions with intense sun exposure, high UV resistance extends liner life far beyond industry norms.
• Installation quality factors: Panel handling, welding techniques and site preparation are as important as the material itself in ensuring system integrity.

Understanding these often-unspoken aspects separates a successful long-term infrastructure investment from short-term fixes.

Conclusion and Why Ocean Non Wovens is the Right Partner

At Ocean Non Wovens, we combine industry-leading HDPE geomembrane products with engineering expertise to deliver robust, long-lasting solutions for water containment challenges. Our supply and installation of the Ocean HDPE Liner 1000 Micron for the Pond Lining project in Surat, Gujarat demonstrates our commitment to quality, reliability, and performance. With a focus on client needs and adherence to best practices, Ocean Non Wovens remains a trusted partner for geosynthetic solutions across infrastructure, agriculture, and environmental applications. If you are planning a water containment project and require expert guidance on product selection and execution, contact us for tailored solutions that deliver real value over the long term.