Case Study: Strengthening Infrastructure for the Reliance Bio-Energy Project with Ocean Biaxial Geogrid 30 kN

Project Overview

The Reliance Bio-Energy Project represents a major step toward expanding India’s renewable energy and sustainable fuel infrastructure. Large-scale bio-energy facilities require heavy civil engineering support systems including stabilized access roads, load-bearing working platforms, and reinforced foundation bases that can withstand constant vehicular movement, heavy equipment loads, and long-term settlement pressures.

Ocean Non Wovens was engaged as a geosynthetics manufacturer and supplier to provide a reliable ground stabilization and reinforcement solution to meet these demands. For this project, we supplied and supported the installation of Ocean Biaxial Geogrid – 30 kN, covering a total application area of 29,000 square meters. For confidentiality reasons related to project operations and client agreements, the exact project location is not disclosed.

The Ground Engineering Challenge

Bio-energy complexes typically face unique soil and structural challenges. Such facilities are often developed on expansive or reclaimed land areas where:

• Subgrade soils show moderate to low bearing capacity
• Repeated heavy axle loading leads to accelerated rutting
• Seasonal moisture variations cause shrink–swell behavior
• Settlement differentials threaten pavement integrity
• Long-term maintenance costs rise rapidly due to surface failures

According to the Indian Roads Congress (IRC:SP:59) guidelines, weak and flexible subgrade conditions require mechanical stabilization systems such as geogrids to enhance pavement performance and improve load distribution capacity across soil layers.

Additionally, studies published by the Federal Highway Administration (FHWA) state that geogrid reinforcement can improve pavement service life by between 30% to 60%, while reducing aggregate thickness requirements by up to 30%, resulting in both cost savings and lower environmental impact.

Product Used: Ocean Biaxial Geogrid – 30 kN

For this project, the engineered solution centered around the deployment of Ocean Biaxial Geogrid 30 kN, a high-performance polymer grid specifically designed for soil reinforcement and pavement stabilization.

Key Technical Properties

• Tensile strength: 30 kN/m in both machine and cross directions
• Junction efficiency: > 90% (ensuring load transfer integrity)
• Aperture design optimized for effective aggregate interlock
• Manufactured from high-strength polypropylene polymers
• Excellent chemical resistance to acids, alkalis, and biological agents
• UV stabilization for durability during extended exposure

According to the Geosynthetic Institute (GSI) specifications, biaxial geogrids are primarily used for:

• Base course reinforcement
• Subgrade stabilization
• Construction of working platforms
• Settlement control and load dispersion

These attributes made Ocean Biaxial Geogrid 30 kN an ideal choice for the heavy-duty requirements of the Reliance Bio-Energy Project’s roadways and service platforms.

Scope of Supply

Ocean Non Wovens delivered a total of:

29,000 SQM of Ocean Biaxial Geogrid – 30 kN

The material was deployed beneath granular layers forming the primary load-bearing strata for internal roads, equipment circulation paths, and foundation preparation zones. The geogrid provided immediate stabilization to weak soils while reinforcing the pavement structure against repeated dynamic loading.

Installation Approach

A structured installation methodology was adopted to ensure optimum performance:

Step 1: Subgrade Preparation

Loose materials were removed and the subgrade compacted to achieve uniform bearing capacity. Depressions were corrected to avoid localized stress points.

Step 2: Geogrid Placement

Ocean Biaxial Geogrid rolls were laid directly on the prepared surface with recommended overlaps of 300–450 mm, ensuring full load transfer continuity as recommended by FHWA pavement reinforcement standards.

Step 3: Aggregate Layer Placement

A granular layer of specified thickness was placed over the grid without trafficking directly on the exposed geogrid to prevent displacement or damage.

Step 4: Compaction and Pavement Formation

Mechanical compaction locked aggregates into the geogrid apertures, creating a stabilized composite layer capable of handling high load magnitudes.

Performance Benefits Observed

Based on engineering observations and post-installation reviews, multiple performance improvements were realized:

1. Enhanced Load Distribution

The biaxial grid evenly dispersed axle loads across a wider soil area, minimizing stress concentration and preventing rut formation.

2. Reduction in Aggregate Consumption

Use of geogrid reinforcement enabled optimized layer thickness. As per FHWA data, stabilized pavements can reduce aggregate requirements by approximately 20%–30% without structural compromise.

3. Improved Construction Efficiency

Stabilized working platforms allowed uninterrupted movement of heavy machinery throughout monsoon weather windows, accelerating project timelines.

4. Long-Term Durability

According to IRC and GSI research, reinforced pavements demonstrate significantly lower maintenance frequency, translating to a longer functional service life.

5. Environmental Benefits

Reduced raw aggregate use resulted in a measurable decline in quarry extraction demand and transportation emissions, supporting sustainability goals aligned with renewable energy infrastructure development.

What Most Companies Don’t Talk About – Real-World Geogrid Applications

While many discussions focus on tensile strength numbers, real project success often depends on overlooked execution factors:

1. Subgrade Uniformity Matters More Than Grid Strength

Geogrids cannot compensate for poorly prepared subgrades. Thickness irregularities or uncompact layers dramatically reduce reinforcement efficiency regardless of grid ratings.

2. Aggregate Compatibility Is Critical

Interlock performance depends heavily on aggregate gradation. As supported by FHWA research, angular aggregates with particle sizes matching geogrid aperture dimensions provide optimal mechanical bonding.

3. Overlap and Alignment Errors Reduce Load Transfer

Small mistakes during roll placement, such as insufficient overlap or misalignment under curves, can create discontinuities that compromise stress dispersion.

4. Trafficking on Exposed Grids Causes Early Failures

Direct vehicle movement before aggregate cover leads to junction fatigue and localized damage, a commonly ignored site error during accelerated construction schedules.

5. Long-Term Cost Analysis Beats Initial Material Cost

The slightly higher upfront cost of geogrid systems is routinely offset by reductions in pavement reconstruction, aggregate quantities, and downtime maintenance over the project lifecycle.

These onsite realities separate theoretical design performance from field results and underscore why skilled product selection combined with proper installation support is essential for project success.

Results Summary

The application of Ocean Biaxial Geogrid 30 kN across 29,000 SQM successfully delivered:

• Higher bearing capacity over weak soils
• Extended pavement performance life
• Reduced rutting and settlement risks
• Lower aggregate consumption
• Improved sustainability metrics
• Faster construction progression

These outcomes align closely with documented global performance benchmarks published by the FHWA, Geosynthetic Institute, and IRC pavement reinforcement guidelines.

Conclusion

The Reliance Bio-Energy Project highlights how advanced geosynthetics play a vital role in modern infrastructure development. By reinforcing foundational layers with Ocean Biaxial Geogrid, the project achieved durable stabilization in challenging soil conditions while keeping environmental and economic priorities in focus. The success of this application reinforces the growing acceptance of geogrid reinforcement as a technically proven and cost-efficient solution for large-scale industrial infrastructure.

Partner with Ocean Non Wovens for Proven Geosynthetics Solutions

At Ocean Non Wovens, we don’t just manufacture geosynthetics, we engineer ground improvement solutions backed by data, expertise, and real-world field experience. From site assessment and product recommendation to material supply and installation support, our team ensures every square meter works exactly as it should. If you’re looking to strengthen your next infrastructure or renewable energy project with reliable geosynthetic systems, connect with Ocean Non Wovens and build on a foundation designed to last.