Perforated 3D Honeycomb Geocell - Reinforcement of Heavy-Haul Haulage Roads in Mines

Perforated 3D Honeycomb Geocell - Reinforcement of Heavy-Haul Haulage Roads in Mines

1. Project Location: Tropical Rainforest Mining Area

2. Project Challenges

The subgrade consists of mine clay, which becomes saturated and softened for extended periods in rainy seasons. Frequent passage of heavy-duty dump trucks causes severe rutting and mud pumping on the original dirt road, necessitating weekly shutdowns for maintenance. Long-distance transportation of crushed stone for subbase incurs extremely high costs.

3. Selected Product

Perforated HDPE 3D honeycomb geocell, height: 200 mm, sheet thickness: 1.6 mm, welding spacing: 380 mm

4. Design Scheme

1. Level the foundation base and lay non-woven geotextile as separation layer.

2. Stretch and fix the 3D honeycomb geocell, secured with metal anchor pins.

3. Use local materials; fill geocell cells with local river sand and crushed stone, compacting in layers.

5. Implementation Results

✅ A monolithic slab with three-dimensional lateral confinement is formed, increasing subgrade bearing capacity by 2.8 times.

✅ Perforations in geocells enable internal drainage, eliminating ponding and springy soil on soft foundation.

✅ Local filling materials reduce the demand for externally transported crushed stone by 65%.

✅ No obvious rutting after years of operation; road maintenance frequency cut by 75%, no emergency road closures in rainy seasons.