Case Study: Enhancing Road Durability on the Vadodara-KLM Expressway Using Ocean HDPE Geocell 

For the Vadodara-KLM Expressway in Gujarat, Ocean Non Wovens supplied 15,000 SQM of Ocean HDPE Geocell (75*712 mm) for ground stabilisation and soil reinforcement under the pavement. The geocells confine granular fill over weak subgrade so the road can carry heavy freight traffic with less base material.

Project overview

• Project: Vadodara-KLM Expressway
• Location: Vadodara, Gujarat
• Product used: Ocean HDPE Geocell (75*712 mm)
• Quantity: 15,000 SQM

The expressway is a high-speed corridor built for heavy axle loads. Freight traffic of this kind often causes early pavement distress in conventional road sections. At the Vadodara site, the subgrade had three problems:

• Poor load-bearing capacity
• Susceptibility to differential settlement
• Waterlogging risk during the monsoon

Ocean HDPE Geocell was used to reinforce the ground over these weak zones.

Why Ocean HDPE Geocell (75*712 mm)

A geocell is a three-dimensional honeycomb of high-density polyethylene strips. Expanded on site and filled with granular material, it forms a composite layer that:

• Stops the fill moving sideways under load
• Reduces vertical and horizontal deformation
• Spreads wheel loads over a wider area of subgrade

The designation 75*712 mm refers to a 75 mm cell height and a 712 mm spacing between welds along the strips. The specification supplied for this project:

HDPE is not attacked by soil microbes and holds its properties across the temperature range found in Indian climates. A 75 mm cell is a shallow section, suited to reinforcing a granular sub-base layer rather than building a deep load platform.

Installation on the expressway

The geocell system was laid across subgrade areas identified as structurally weak, in four stages:

1. Site preparation: clearing and compacting the base soil.
2. Geocell installation: laying the Ocean HDPE Geocells and expanding them to full width.
3. Infill placement: filling the cells with locally available granular sub-base (GSB).
4. Compaction and layering: compacting with vibratory rollers for a uniform surface.

Confined in the cells, the GSB acts as a stiff mattress. The fill cannot spread sideways, so more of the load is carried by the reinforced layer and less reaches the weak subgrade. On fine or wet subgrades, a non woven geotextile separator under the geocell is commonly added to stop soil pumping up into the fill.

Performance

Geocell reinforcement allows a thinner base layer to carry the same load as a thicker unreinforced one. On the Vadodara-KLM Expressway, the geocell let the designers reduce layer thickness while maintaining load-bearing performance. Geocells are covered in India’s IRC:SP:59 guidelines for geosynthetics in road pavements.

Other advantages

• Faster construction: less deep excavation and fewer base layers to place and compact.
• Lower carbon footprint: local fill can replace imported aggregate, cutting transport emissions.
• Recyclable material: HDPE is a recyclable polymer.
• Drainage: perforated cell walls and free-draining granular infill let water move laterally out of the layer instead of sitting under the pavement.

Local impact and maintenance

The project used locally sourced fill, which lowered cost and brought work to nearby suppliers. Reinforced roads need less maintenance, so there are fewer closures for commuters and logistics vehicles. Keeping the base stiff also limits the rutting and potholes that develop when unbound layers deform.

Geocells from Ocean Non Wovens

Ocean Non Wovens supplied 15,000 SQM of Ocean HDPE Geocell (75*712 mm) for the Vadodara-KLM Expressway. We supply geocells and other geosynthetics for highways, haul roads and urban pavements, with quality checks in manufacturing and technical support through the project. For more road projects, see our case studies.

Need technical support for your next infrastructure project? Contact Ocean Non Wovens and our engineering team will help you choose the right geocell.