GEOWEB® Geocell Installation: Answers to Common Field Questions

Posted April 22, 2026 by Katie Bocskor

Thank you to all who participated in our recent webinar, “Best Practices for Installing the GEOWEB® Geocell System,” and for submitting your technical questions regarding GEOWEB® Geocells.

Based on the discussion and submitted inquiries, we’ve compiled answers to some of the most frequently asked topics to help clarify how the GEOWEB system works and where it delivers the greatest value.

If you didn’t catch the live webinar, view the on-demand webinar here.

Q1. How difficult is it to maintain a failed subgrade with GEOWEB Geocells?

Subgrade failure can look very different from project to project, which means the level of remediation required also varies. In many cases, a failed subgrade can be stabilized relatively easily using the GEOWEB Geocell System and full removal or amendment may not be required.

To eliminate uncertainty, we offer a free project evaluation service. By submitting basic project details, our engineering team can review the conditions and recommend an appropriate solution.

Start your project evaluation here: https://www.prestogeo.com/free-project-evaluation/

Q2. Why is geotextile fabric installed first?

In standard construction sequencing, the geotextile is installed beneath the GEOWEB Geocells, with thickness and material type selected based on the application, loading conditions, and surface characteristics.

When a high-strength or high-performance woven geotextile is used, it also helps prevent soil clogging and can provide additional structural benefit. Placing the fabric below the geocells allows it to function as intended throughout the life of the installation.

Our engineering team can recommend an appropriate geotextile based on your specific project requirements and site conditions. Submit your project details to receive a free evaluation: https://www.prestogeo.com/free-project-evaluation/

Q3. How much material must be placed over the top of the GEOWEB system?

For load support applications, a wear surface is typically required about the GEOWEB Geocell material. The thickness and material type depend on the application, loading conditions, and surface type.

All load support designs will include some form of surface protection. In other applications, such as concrete channel armoring, the concrete surface will be flush with the top of the geocell. Overall, cover requirements vary depending on design and conditions.

Q4. Are the ATRA® Stakes driven through the underlayment?

The answer is yes. Whether the application involves load support, slopes protection, or channels armoring, the stakes are typically driven through the geotextile underlayment as part of the standard installation process to help secure the system during placement and infilling.

Q5. What is the typical design life of GEOWEB Geocells?

The design life can be tailored to meet project requirements. Many roadway projects require a 20-year design life, while other civil or infrastructure applications require 50 to even 100 years.

The GEOWEB Geocell material has been tested to withstand environmental exposure for up to 149 years without degradation. Because GEOWEB system is most often buried and not fully exposed to UV or environmental extremes, its real-world service life is typically even longer.

Q6. How high can you go with a GEOWEB Earth Retention Wall?

For geogrid-reinforced earth retention walls, there is effectively no height limit, provided there is adequate space for proper tieback reinforcement. Tiebacks typically extend 70% of the wall height. When terracing is possible and sufficient reinforcement length is available, GEOWEB Walls can support extremely tall structures.

We’ve completed several impressive high-wall projects over the years. You can explore some of these case studies in our Geosystems Project Gallery: https://www.prestogeo.com/gallery_presto/products/soil-stabilization/geoweb-retaining-walls/?type=casestudy

Q7. Do you perform overturning analysis and global stability checks for earth retention systems?

Yes, analysis capabilities are available, but the level of design support depends on project needs. In some cases, an independent geotechnical engineer may be required. Providing more information such as soil properties, seismic coefficients, and site conditions allows for a more complete evaluation.

The more information provided, the more complete and accurate the analysis can be. We also offer a free MSE Wall Design Software for those who prefer to complete calculations themselves, or our experienced engineering team can assist with a project evaluation.

Request the free MSE Wall Design Software here: https://www.prestogeo.com/design/soil-stabilization/geoweb-mse-wall-software/

Q8. Does the GEOWEB Geocells come in different colors (e.g., green or blue) to blend with nature?

Standard GEOWEB geocell material is black, due to carbon black stabilization, which enhances durability and long-term performance.

For projects where aesthetics matter, especially earth retention applications, colored fascia options are available in a tan or green finish to blend more naturally with surrounding environments. If you have a specific color requirement, custom options may also be possible depending on the project.

Let’s Keep the Conversation Going

We received even more questions than we could address during our webinar allotted time, and we appreciate the strong engagement from everyone who participated. If we didn’t get to your question or if you’d like help with a specific project, we’d love to hear from you.

You can reach us directly using the contact information provided during the session, or email [email protected] to get started with a free project evaluation.

Advancing Rail Resilience: How Geosynthetics Help Achieve CRISI Objectives for Robust and Stable Infrastructure

Posted April 20, 2026 by Ashley Beyer

train along track stabilized with geoweb geocells

Discover the Latest CRISI Rail Infrastructure Funding Opportunities: Apply Before the June 2026 Deadline

The U.S. Department of Transportation is bolstering rail infrastructure advancements through the Consolidated Rail Infrastructure and Safety Improvements (CRISI) program. With a recent allocation of more than $2 billion, the CRISI program is set to significantly impact rail safety, efficiency, sustainability, and reliability across the United States.

This funding initiative is designed to support a variety of projects that are pivotal to enhancing the nation’s passenger and freight rail systems. It represents a call to action for rail industry professionals, including engineers, planners, and project managers, to leverage this opportunity to advance their rail infrastructure projects.

The deadline for application submissions is 11:59 p.m. ET, June 22, 2026. Professionals in the rail sector are urged to prepare their proposals that align with CRISI’s mission to improve the rail infrastructure’s overall landscape.

For a comprehensive overview of the application process and to assess project eligibility, stakeholders are encouraged to review the Fiscal Years 2025-2026 Notice of Funding Opportunity (NOFO) available through the CRISI program. This funding presents a pivotal chance for those involved in rail infrastructure to gain the support and resources needed to propel their projects forward.

The GEOWEB® Soil Stabilization System (Geocells): A Proven Solution for Rail Infrastructure

Mainline Ballast Reinforcement

The GEOWEB Rail Ballast Stabilization System stands out as an innovative solution for addressing ballast stabilization challenges, creating a more resilient and stable layer underneath the track. The 3D geocellular system yields unparalleled performance and construction benefits, surpassing the capabilities of 2D methods like planar geogrids or Hot Mix Asphalt (HMA), especially in areas with soft subgrades.

The performance of the GEOWEB system is backed by extensive research and rigorous field testing at renowned institutions such as TTCI and Oregon State University. It has demonstrated its ability to reduce settlement and track displacement under the strain of heavy freight loads on soft subgrades, and has already been adopted for use in railway track beds by international authorities in other advanced nations, such as Network Rail in the United Kingdom, with their recent published guidance on “The Use of Geocells in the UK Railway Track Bed”. Additionally, SmartRock testing by the University of Kansas revealed significant reductions in ballast abrasion, movement, and rotation, as further evidence the life of the ballast can be extended when the right geosynthetic product is incorporated into the project design.

Bridge Approaches, Crossings, Diamonds: Ballast Reinforcement in High-Stress Areas

Areas like bridge approaches, diamonds, turn-outs, and crossings face immense stress and usually require a lot of upkeep. The GEOWEB Soil Confinement System helps lower the need for maintenance in these challenging spots. It strengthens the ballast layer, reduces movement and deflection, and cuts down on maintenance in these crucial transition zones.

GEOWEB Geocells: BABA-Approved

Last year, the White House provided guidance on the Build America, Buy America (BABA) initiative. BABA specifies certain products must be manufactured in the United States to qualify for federal funding under the IIJA.

Selecting the GEOWEB System for enhanced track stabilization allows projects to achieve improved resilience and longevity, ensuring compliance with the standards set by the CRISI program, the Infrastructure Investment and Jobs Act, and Build America, Buy America. Presto Geosystems is ISO 9001 certified, and the GEOWEB Soil Stabilization System is 100% U.S. made. (A copy of our Certificate of Registration can be provided upon request.)

Need Assistance with Your Rail Projects?

Presto Geosystems offers free project planning support for all GEOWEB Geocells applications in rail projects. Our experienced engineers are ready to assist with project evaluations to ensure your project’s success from start to finish. If you’re dealing with challenges related to soil stabilization or looking for innovative track stabilization solutions, please reach out to us.

Building Commercial Truck Parking Lots That Last

Posted August 19, 2025 by Ashley Beyer

A smarter way to build and maintain heavy-duty parking lots

When you plan or purchase a commercial truck parking lot, you need it to perform reliably year after year. Issues like potholes, rutting, and poor drainage are more than cosmetic. They disrupt operations, increase maintenance costs, and shorten the lifespan of the lot.

Fully loaded trucks, frequent turning, and long parking times create constant stress on the surface. Traditional asphalt or aggregate designs often struggle under these conditions, which can lead to repairs much sooner than expected.

The GEOWEB® Soil Stabilization System addresses these challenges from the start by reinforcing the base so the surface stays stable and your yard remains operational.

Close-up view of GEOWEB geocells used in parking lot base reinforcement

The challenge for truck parking areas

Commercial truck parking areas experience extreme loads, tight turning, and long dwell times. Traditional asphalt or aggregate surfaces often fail under these conditions, which leads to higher upkeep and disruption.

Constant pressure from heavy trucks
Turning movements that grind and displace materials
Soft subgrades that shift and settle over time
The need to manage stormwater without sacrificing performance

Many lots appear to perform well after construction but begin developing costly problems within a few seasons.

The GEOWEB System solution

The GEOWEB system reinforces the base layer with a three-dimensional honeycomb-like structure that confines aggregate and spreads loads over a larger area. The result is a stable surface that resists deformation and reduces required pavement and base depths.

Key benefits for commercial truck parking

Pavement and base thickness reduced by up to 50 percent
Longer-lasting surfaces with fewer repairs
Significant reduction or elimination of potholes and rutting
Options for permeable or impermeable designs to manage stormwater
Faster installation with minimal equipment

Where it works

Commercial truck stops, rest areas, and travel centers
Long-haul and overnight parking lots
Trailer drop yards and staging areas
Distribution centers and fleet yards
Bus and utility vehicle parking

Truck Parking Lot - Request Information

Tell us a little about your project and we will follow up with the right guidance and next steps.

Name
This field is for validation purposes and should be left unchanged.
Contact Information
First name*
Last name*
Company*
City
State/Province
Email*
Phone
Approx. lot size
Surface type
What would you like help with?
- Design guidance
- Spec review
- Pricing
- Permeable Options
Other information about the project
Check the box to accept our privacy agreement.*
- Yes, I agree to the terms and conditions.
CAPTCHA

GEOWEB Geocells Meet the Demands of Remote Wind Farm Construction

Posted June 18, 2025 by Ashley Beyer

Remote wind farm projects often face challenging site conditions, including soft soils, steep terrain, and limited access to construction materials. Building reliable infrastructure in these environments requires solutions that are both technically sound and environmentally sustainable.

Soil Stabilization Solutions for Wind Farm Roads & Platforms with GEOWEB® Geocells

The GEOWEB Soil Stabilization System offers a proven approach for creating stable access roads, crane pads, and work platforms in challenging environments. The three-dimensional geocell structure confines and distributes loads effectively, reducing stress on subgrades. This minimizes the need for over-excavation and decreases reliance on imported aggregate, making it a cost-effective and environmentally responsible choice.

Building Access Roads, Crane Pads, and Work Platforms Over Soft Soils

The GEOWEB Geocells are ideal for areas with soft or saturated soils where traditional methods may be costly or prone to failure. The system allows for the use of locally available fill, reduces hauling needs, and supports heavy loads without rutting or base failure. This makes it an ideal solution for stabilizing access routes and critical lift zones during turbine installation.

Long-Term Performance in Cold Climates and Snowy Conditions

In cold climates and snowy regions, GEOWEB Geocells maintain structural integrity and promote drainage. This helps prevent surface degradation, reduces long-term maintenance, and keeps essential access points operational during harsh weather conditions.

Supporting Sustainable Development in Remote Wind Farms

These types of site conditions are common in renewable projects across Canada and the northern U.S., including recent developments like the Mesgi’g Ugju’s’n 2 (MU2) Wind Farm in Quebec. Located in the Gaspésie region and developed in partnership with Mi’gmaq communities, the project highlights the importance of building durable, low-impact infrastructure that supports both environmental goals and long-term performance in remote areas.

Funded in part by the Canada Infrastructure Bank, the MU2 project reflects the growing trend toward Indigenous-led renewable energy development. With remote terrain, cold weather, and sustainability goals in focus, this type of project represents the real-world demand for smarter infrastructure solutions like GEOWEB Geocells.

Get a Free Project Evaluation and Value Engineered Recommendation for Your Wind Project

If your team is planning or supporting a wind energy project in similar conditions, our in-house engineering team can provide project support to help you meet performance and sustainability goals with value engineered solutions designed for challenging environments. The GEOWEB geocells have an Environmental Product Declaration so you may build with quality materials you trust, knowing their life cycle impact.

Request a free project evaluation to learn how the GEOWEB Geocells can support your next renewable energy project.

Dam Structure Safety Installation and Repair Using Advanced Geosynthetic Technology

Posted May 22, 2025 by Ashley Beyer

Written By: Samantha Justice, P.E.

Dams and Spillways Are a Critical Part of U.S. Infrastructure

With over 91,000 structures nationwide, dams and spillways are essential for controlling flooding, water distribution, and providing hydroelectric power. However, these structures cannot last forever. The average age of dams and spillways in the U.S. is now 61 years, which is significantly over the typical 50-year lifespan of these structures. Aging infrastructure can lead to serious consequences if safety precautions are not taken or measures are not implemented to address identified problems promptly. Continual inspection and upkeep are crucial for any dam manager.

The 2025 Infrastructure Report Card by the American Society of Civil Engineers upgraded the condition of U.S. dams from a “D” to a “D+”, reflecting modest improvements but still highlighting the critical need for ongoing repairs and maintenance. State and federal regulations provide a framework for assessing and maintaining dam and spillway structures, requiring at least yearly audit inspections to identify areas needing repair or replacement. Performing these repairs can help extend the lifetime of dams, maintaining essential services without excessive costs or increased failure potential.

Understanding Areas of Concern for Existing Structures

The vast majority of America’s rivers and lakes have existing dams and spillways, and as such, very few new structures are being built. With new construction, safety measures can be incorporated during the design phase to extend the lifetime of the project and help prevent failures. The true threat is with existing structures that have gone past their intended lifetimes or have seen areas of potential failure.

A recent example of the potential for catastrophic damage due to a dam failure is the 2017 Oroville Dam crisis in Northern California. Extremely heavy rainfall over a number of days raised the level of Lake Oroville, increasing the flow over the main spillway to above-average levels. Almost immediately, damage was observed in the lower half of the spillway, with a large section of the concrete path collapsing. The emergency spillway was utilized to help prevent further damage to the main spillway; however, excessive erosion occurred to the emergency spillway path, and emergency repairs were subsequently required to address damage in both spillway areas.

Further damage occurred when more rainfall increased the lake level yet again, including blocking the downstream river and requiring the immediate shutdown of the Oroville hydroelectric power plant. Luckily, total collapse of the dam did not occur, but more than 180,000 residents of the Feather River Basin were required to evacuate for multiple days, and over the next year, more than 1,000 people worked more than 2 million hours to rebuild the spillways to ensure the safety of downstream communities.

With federal funding support from the Infrastructure Investment and Jobs Act (2021), states have access to resources for upgrading aging dams and spillways before failures occur. For example, the Oroville Dam crisis in 2017 followed the rejection of a 2005 proposal to build a concrete emergency spillway — an upgrade that could have prevented the damage.

Re-evaluating existing structures to ensure they can withstand 100-year and 500-year flood events remains essential. Regular maintenance of upstream and downstream dam faces, spillways, and even work pads and access roads supports safety by enabling faster inspections and repairs. These proactive steps help extend the lifespan of critical infrastructure and reduce the risk of costly emergencies.

GEOWEB® Geocells Are a Repair Solution for Dams and Spillway Sites

GEOWEB geocells offer long-term solutions for common dam and spillway challenges. Geocells function as the support structure for unpaved roadways, capable of supporting maintenance and repair vehicles. They also function as surface erosion control solutions, preventing the formation of rills or the collapse of unstable soils due to water flow, wave action, and storm events.

GEOWEB geocells can be placed on the upstream face of a dam structure to mitigate the effects of wave action on the dam, supporting existing riprap areas, or replacing them entirely with vegetation, gravel, or concrete. The flexibility of the GEOWEB system allows for the use of mixed infill materials, such as topsoil above normal water levels for grass growth and small aggregate below the water level for erosion prevention. Comprised of high-density polyethylene (HDPE), GEOWEB geocells are formulated for long term durability to resist weathering, chemical attack, and ultraviolet radiation, and are therefore suitable for use in applications where the material will be subjected to cyclic wetting and drying, permanently submerged, or full sun exposure. The material is not prone to degradation or corrosion due to environmental factors and can be placed on the downstream face or within a spillway structure. The system is also compatible with concrete infill to accommodate extremely high flow velocities. For comparison, Table 1 summarizes allowable velocities and shear stresses for various channel lining alternatives.

Comparison of allowable velocity and shear stress for channel lining alternatives

In emergency spillway areas, topsoil infill with vegetation can be used to allow for a natural camouflaged look, while still preventing erosion and uncontrolled water flow, and outperforming traditional unreinforced channel lining alternatives.

Staging areas and maintenance roads are also integral parts of a dam site, and when necessary, these features provide vital access and adequate ground support for vehicles and heavy equipment to perform inspections, routine maintenance, and repairs. The GEOWEB system can be used in a variety of load support applications, including unpaved access roads, laydown areas, and parking lots. Reinforcing these roads means significantly reduced maintenance requirements, reduced rutting, and access to areas that might otherwise be unable to support heavy loads due to soft soil conditions. Minimizing stresses on top of dam structures is critically important to preventing the formation of cracks or slumps within the structure that could lead to failure. The GEOWEB road system can be integrated with the slope protection system on the upstream and downstream faces of the dam for a continuously protected berm from water, vehicle, and impact loads.

Design Support & Resources for the GEOWEB System Applications

The engineering team at Presto Geosystems works closely with engineers and project planners, offering free project evaluation services and on-site support. Our recommendations will deliver a technically sound, cost-effective solution based on four decades of accredited research and testing data. Please contact our knowledgeable staff and network of qualified distributors and representatives to discuss your project needs today.

ASCE Reveals the 2025 Infrastructure Report Card

Posted April 11, 2025 by Ashley Beyer

The American Society of Civil Engineers (ASCE) recently released their quadrennial Infrastructure Report Card. America’s infrastructure earned an overall grade of C, which is a minor improvement over 2021’s grade of C-minus and the highest grade received since the report card’s inception in 1998. While the report card is trending in the right direction, we are not quite ready to hang it on the fridge.

There is still a lot of work and investment required to make up for decades of underinvestment and deferred maintenance, especially as climate change, population growth, and aging systems continue to place added stress on our infrastructure. Without sustained funding, strategic planning, and public-private collaboration, many critical systems — from levees and roads to drinking water and stormwater management — will remain vulnerable and inefficient.

The report card assesses and assigns grades to 18 categories of American infrastructure, including Bridges, Energy, Ports, Rail, Roads, and Stormwater. Half of the categories received a grade in the “D” range. This means that the civil engineers who evaluated these categories determined that the infrastructure is “poor, at risk.” According to the report card, this is, “…a clear sign that more needs to be done to improve the health of America’s built environment.”

Categories that received a grade in the “D” range include Dams, Energy, Levees, Roads, Schools, Stormwater, Transit, and Wastewater. These systems are critical to the overall health and wellbeing of our communities, and vital to commerce and economic stability at local, regional, and national levels.

Solutions to Improve America’s Infrastructure Grade

The 2025 Infrastructure Report Card underscores that while recent progress is promising, significant challenges remain. Federal investment through landmark legislation like the Infrastructure Investment and Jobs Act (IIJA) and the Inflation Reduction Act (IRA) has helped reverse decades of stagnation, but the work is far from done. According to ASCE’s 2024 Bridging the Gap study, an additional $2.9 trillion is still needed across 11 infrastructure sectors to reach and maintain a state of good repair — a level that would earn a “B” on the Report Card.

Closing this investment gap won’t just result in higher grades, but it will also create tangible economic relief for American families. If Congress maintains recent funding levels, the average household could save $700 annually by avoiding the hidden costs of failing infrastructure, such as delays, emergency repairs, and increased utility and transportation expenses.

Meanwhile, climate-related threats continue to intensify. Infrastructure systems, particularly aging roads, levees, dams, and water networks, face mounting risks from flooding, hurricanes, wildfires, and extreme temperatures. Investing in resilience now means fewer rebuilds later, and more reliable infrastructure to support economic growth and public safety.

Building Resilient Infrastructure with Geosynthetics

The future success of many infrastructure projects depends on the strength of the underlying soil. Through an interconnected honeycomb-like network, 3D geocells confine and stabilize soils that would otherwise be unstable under loading. The GEOWEB® 3D Soil Stabilization System is the industry’s first and most complete geocell system, designed with fully engineered components to withstand the most challenging site conditions. These accessories are engineered for strength, fast installs, and reliable long-term performance.

Whether used for load support, channel protection, slope stabilization, stormwater management, or retaining wall systems, the GEOWEB system enables cost-effective, low-maintenance infrastructure that stands up to environmental stresses. Its flexible design and engineered accessories ensure fast installation and long-term performance, even under challenging conditions.

At Presto Geosystems, we support engineers and project owners with free project evaluation assistance and technical guidance from project start through construction.

Learn more about how the GEOWEB geocells can be used to improve resilience in the lowest-graded categories.

Download the full 2025 Infrastructure Report Card >>

Presto Geosystems Announces Environmental Product Declaration (EPD) for Geocells

Posted April 10, 2025 by Katie Bocskor

With the commercialization of geocell soil confinement technology in the early 1980s, Presto Geosystems made history as one of the early pioneers in the world of geosynthetics. Over four decades later, that innovative spirit is as alive today as it was at the beginning of our journey. Presto Geosystems, the leader in geocell technology, announces the publication of the industry´s first Environmental Product Declaration (EPD) for geocells. This milestone reinforces Presto Geosystems’ ongoing commitment to reliable infrastructure and environmental quality.

What is an Environmental Product Declaration?

An EPD is a transparent, objective report that communicates what a product is made of and how it impacts the environment across its entire life cycle. The EPD, based on rigorous life cycle assessment (LCA) methodology, provides a comprehensive overview of the environmental impacts associated with the production, use, and disposal of Presto Geosystems’ GEOWEB® geocell system. This independent declaration includes key metrics such as carbon dioxide performance, energy consumption, and natural resource usage, all of which are vital factors influencing the overall environmental footprint of soil stabilization and erosion control solutions in civil and structural applications.

The EPD follows established international standards, including ISO 14025, lending to the credibility and consistency of the environmental data.

This initiative aligns with parent company Reynolds Consumer Product’s Sustainability commitments for Green Circle certification and efforts to improve documentation for environmental impact, and to reduce emissions, CO2e, and waste.

By providing detailed environmental impact information, Presto Geosystems is empowering engineers, consultants, architects, and project owners to make choices that align with their sustainability goals.

The EPD for the GEOWEB system is now available for download here >>

Patented GEOWEB Geocell System

Our patented GEOWEB Soil Stabilization System been installed on thousands of projects in every geographic region in the world and is the only geocell technology that has stood the test of time for over 40 years.

For more information, contact:
JP George, MS, CPESC-IT
Business Manager, Presto Geosystems
[email protected] | +1-920-475-7957

Building a Resilient U.S. Supply Chain for Critical Materials & Mining Infrastructure

Posted February 7, 2025 by Ashley Beyer

Written by: JP George, Business Manager

The U.S. Dept of Energy (DOE) classifies critical materials and minerals based on their importance to energy and supply risk. With the new U.S. administration taking office in January 2025, there has been a renewed effort to focus on strengthening the supply of these resources both domestically and abroad.

Strengthening Domestic Supply

Bipartisan efforts continue to bolster domestic mineral production through legislative actions, such as the proposed Critical Mineral Consistency Act of 2025 and revisions to the Energy Act of 2020. The National Mining Association (NMA) supports these measures, emphasizing the need for U.S. production over reliance on foreign sources.

According to the U.S. Geological Survey’s (USGS) 2025 Mineral Commodity Summaries, the U.S. remains import-reliant for many critical minerals, with China controlling production for over two-thirds of these resources. NMA President & CEO Rich Nolan states, “We could be producing most of these minerals here at home—under world-leading environmental, labor and safety standards”.

Projects like Perpetua Resources’ Idaho gold project could supply up to 35% of the U.S. annual demand for antimony, demonstrating the potential for revitalized domestic mining.

Innovations in Mining & Mineral Processing

Technological advancements are driving sustainable mining operations:

South32 Hermosa Project and the Battery Materials Development Grant are funding domestic manganese production for EV battery materials.
Argonne National Lab is developing methods to make more batteries with fewer materials, reducing reliance on foreign sources. Jeff Spangenberger from Argonne hopes to make “more efficient use of critical materials in domestic battery supply chains so that the U.S. can rely less on other countries to achieve its clean energy goals”.
The World Economic Forum’s Energy Transition Innovations report highlights groundbreaking technologies such as:
The Helios Cycle: A closed-loop sodium system that eliminates CO₂
Kofiln’s Exothermic Copper Processing: A method that significantly reduces SO₂

Innovative Soil Stabilization for Mining Operations

Beyond advancements in mineral extraction, innovations in soil stabilization are enhancing efficiency and safety in the mining industry. The GEOWEB geocells provide three-dimensional confinement and strengthening of infill, delivering:

increased speed of operation,
lower maintenance,
safer installation, and
a lower total cost of ownership.

Developed by Presto Geosystems, the original inventors of geocell technology, the GEOWEB geocells have been made in the USA for over 45 years. Their proven applications in the mining sector include:

Haul Roads & Site Access Roads – Providing stability over soft ground, both above and below grade.
Stormwater Containment & Channel Armoring – Controlling and containing runoff while protecting environmental barriers.
Geomembrane Protection – Reinforcing basins, tailings storage, and heap leach pads.
Mine Slope & Site Reclamation – Stabilization slopes for long-term restoration.

GEOWEB Geocells Proven Performance in Large-Scale Mining Applications

North Antelope Rochelle Mine (WY): The world’s largest coal mine by reserves relies on GEOWEB geocell-reinforced roads to withstand the demands of 400-ton payload ultra-class haul trucks. View project photos and case study >>
Western U.S. Evaporation Pond Access: Stabilized site access for operations over challenging terrain. View project photos and case study >>
Oxbow’s Elk Creek Mind (CO): Underground haul road stabilization using the GEOWEB geocells. View project photos and case study >>
Idaho Mine & Mill Site: Tailings stabilization and site reclamation for long-term environmental protection. View project photos and case study >>
Cyprus Miami Mine (AZ): Slope reclamation using GEOWEB geocells to secure disturbed land. View project photos and case study >>

Backed by Engineering & Research Excellence

As a leader in geocell technology, Presto Geosystems integrates over 40 years of accredited research and testing to ensure structural integrity and cost-effective solutions. Our in-house engineering team applies research findings to develop practical, real-world applications for the mining industry.

Get a Free Project Evaluation

Are you looking for a reliable, long-term stabilization solution for your mining operation? Our Free Project Evaluation service offers expert recommendations tailored to your specific needs.

How Geocells Provide Sustainable Solutions for Soil Stabilization and Erosion Control

Posted October 31, 2024 by Ashley Beyer

Innovative Site Solutions for Civil Engineering and Construction Projects

When faced with challenging site conditions—whether it’s weak soils, steep slopes, or erosion-prone channels—finding an efficient, long-term solution that minimizes maintenance is essential. Geocells offer just that. These innovative cellular confinement systems (CCS) are a proven solution for load support, retaining walls, slope stabilization, and channel protection applications. Geocells not only improve soil stability but also contribute to eco-friendly, sustainable project designs.

Geocells are three-dimensional, honeycomb-like structures typically made from high-density polyethylene (HDPE). By confining and reinforcing infill materials like soil/vegetation, sand, gravel or concrete, geocells create a stable, load-bearing surface. This cellular system prevents soil movement and erosion, making geocells a versatile solution for stabilizing weak soils and supporting structures such as roads, retaining walls, slopes, and channels.

How Geocells Work

The core function of geocells is to create a grid of interconnected cells that confine and stabilize infill materials. This CCS strengthens the underlying soil and distributes loads more evenly, preventing the movement of infill under pressure. In load support applications—such as roads, parking areas, or driveways—geocells act like a semi-rigid slab.

The geocell structure increases the load distribution angle and spreads vertical stresses over a larger area, which is commonly referred to as the mattress effect. This feature helps stabilize weak subgrades and prevents surface deformation, such as rutting or differential settlement, under heavy loads.

Key Benefits of Geocells

Soil Stabilization for Weak Subgrades: Geocells are designed to stabilize soils that would otherwise shift or settle under loading. By confining infill materials, geocells create a firm, stable base that can support the demands of roadways, heavy-duty parking lots, or other infrastructure projects. The mattress effect further enhances this stabilization, ensuring that vertical stresses are distributed across a wider area, reducing the likelihood of differential settlement or deformation over time.

Erosion Control for Slopes and Channels: On slopes and in channels prone to erosion, geocells help prevent soil from washing away during rainstorms or high-flow events. The cellular structure holds soil in place, creating long-term stability and reducing maintenance needs.
Sustainable and Eco-Friendly: By allowing the use of locally sourced infill, geocells reduce the need for imported materials and minimize the environmental footprint of a project. Their permeable design also promotes natural water infiltration, helping manage stormwater and reduce runoff.
Cost-Effective with Minimal Maintenance: Geocells are a cost-effective solution for stabilizing weak soils and preventing erosion. Their simple installation process and long-lasting performance mean reduced material costs upfront and less maintenance over time.

Common Applications for Geocells

Load Support: Geocells stabilize unpaved roads, parking areas, and other surfaces by evenly distributing loads, which prevents differential settlement and rutting.
Slope Stabilization: On steep embankments, geocells hold soil in place, reducing erosion while allowing vegetation to take root for natural reinforcement.
Retaining Walls: Geocells offer a flexible alternative to rigid retaining walls, adapting to natural shifts in the landscape and soft sub grade soils while maintaining soil retention.
Channel Protection: Geocells reinforce the bed and banks of stormwater channels, reducing erosion and ensuring long-term stability, even in high-flow conditions.

retaining wall slope channel and load support geocells

Introducing GEOWEB® Geocells: The Original Cellular Confinement System

While geocells are becoming widely used today, GEOWEB Geocells stand out as the original and most advanced system on the market. Presto Geosystems, in collaboration with the U.S. Army Corps of Engineers, pioneered the development of geocells in the late 1970s to address the need for reliable soil stabilization solutions in military and civil applications. This collaboration resulted in the invention of the GEOWEB system, which continues to lead the industry in performance and innovation over the past 40 years.

GEOWEB Geocells are made from high-quality, virgin HDPE, which offers superior strength, flexibility, and long-lasting durability compared to other systems. This ensures that the GEOWEB Geocells can withstand harsh elements and challenging conditions, whether it’s in load-bearing applications or erosion control projects.

The GEOWEB system is a complete geocell system, including ATRA® Accessories such as ATRA Connection Keys, ATRA Anchors, ATRA Tendon Clip, and the ATRA Driver. These components are designed to enhance installation efficiency and long-term performance, providing fast, secure connections that ensure the structural integrity of the entire system.

Comprehensive Construction Services, Engineering Support, and Free Project Evaluations

At Presto Geosystems, our commitment goes beyond providing high-quality products. We offer on-site field assistance, engineering support, and free project evaluations. Our team works with you at every stage, from initial project evaluation assistance to on-site installation support, helping you achieve the best results for your specific project challenges.

Understanding Hoop Stress and Wall Tension in Geocells

Posted September 9, 2024 by Katie Bocskor

Written By: Samantha Justice, P.E., Bryan Wedin, P.E.

Geocells provide one of the most powerful solutions available to engineers and contractors when designing and constructing roadways over soft and weak subgrades. With a successful track record of over 40 years, geocells have proven effective in load support applications over challenging conditions. If you’ve ever wondered how geocells work in load support applications – and the relationship between lateral confinement, hoop stress and wall tension – you’ve come to the right place.

Geocells are used to alter vertical stresses beneath an applied cyclical load. When a vertical, cyclical load is applied over geocells, active earth pressures develop in the loaded cell. These pressures arise due to the friction between the infill material and the cell wall. This friction pushes back against the passive earth pressure in the adjacent cells, helping to support the load. Refer to Figure 1. The balance of active and passive earth pressures activates the hoop stress in the cell walls, which increases the stiffness and bearing capacity of infill material. The infill material is confined within the individual cells with no chance of displacement, or lateral or vertical spreading and the result is increased stiffness. In effect, geocells behave more like three-dimensional structures or a semi-rigid slab by increasing the load distribution angle and spreading the vertical stresses over a larger area which is commonly referred to as the mattress effect.

Figure 1

An enhanced woven geotextile separation layer is typically provided under the geocell system and works in conjunction to provide additional load distribution along with filtration, separation, and controlled drainage. With the enhanced woven geotextile, it is possible to construct over extremely weak subgrades with standard penetration resistance (SPT-N) values less than 2 blows per foot (CBR < 0.5%), where planar geosynthetics, such as geogrids, would otherwise fail.

How Does Hoop Stress and Wall Tension Relate to Lateral Confinement?

Hoop stresses develop within the cell walls as earth pressures increase in response to an applied load at ground surface. In other words, the same earth pressures responsible for developing interface friction between the geocell and the infill material also result in hoop stresses with the cell walls. Although not perfectly cylindrical, geocells can be envisioned to behave similarly to an interconnected network of pressurized cylinders, wherein hoop stresses are a function of the net pressure that develops due to the internal and external pressures acting in and around each cell.
In this manner, radial pressures that develop within each cell are resisted by those that develop in the adjacent cells, and hoop stresses may be estimated using the classic equation for hoop stress for a pressurized thin-wall cylindrical vessel:

σ_H = p_net*(D/2t)

Where,

σ_H = hoop stress

p_net = net pressure = p_i – p_e

p_i = internal pressure

p_e = external pressure

D = geocell diameter

t = wall thickness

The active earth pressure in a loaded cell below a cyclical load can be calculated using the Boussinesq stress equation. The interaction between hoop stresses and passive earth resistance in geocell systems was investigated by Emersleben (2009) and observed that lateral pressures in adjacent cells decrease exponentially with increasing distance from the actively loaded, or “source” cell(s) – in effect, defining a pressure gradient. Based on Emersleben’s findings, it is possible to evaluate the net earth pressure that develops between the interior and the exterior of a cell wall, using the thickness of the cell wall as the distance between two points along the defined pressure gradient line. Refer to Figure 2.

Lateral Pressure vs Distance

Figure 2

The largest net earth pressures, and hoop stresses, occur in cells directly beneath the perimeter of the load footprint—the wheel contact area in the case of vehicle loads. Based on this, it is possible to estimate the maximum hoop stresses expected to develop in geocells in response to standard AASHTO load conditions.

Table 1 summarizes the estimated hoop stress and cell wall tensions developed under standard AASHTO load ratings for a 6-inch geocell-reinforced layer with a 2-inch wear surface. The calculated values assume a nominal 9.5-inch diameter geocell infilled with a granular material having an internal friction angle of 32 degrees and unit weight of 120 lbs/ft³.

Hoop Stress and Cell Wall Tension

AASHTO Load Rating	Wheel Load (lbs)	Tire Pressure (psi)	Hoop Stress (psi)	Cell Wall Tension (lbf)
AASHTO H/HS10	8,000	60	44	16
AASHTO H/HS15	12,000	85	63	23
AASHTO H/HS20	16,000	110	82	30
AASHTO H/HS25	20,000	125	96	34

Table 1

The corresponding tensile forces that develop under working load conditions are relatively modest due to the lateral confinement effect of the adjacent cells. When compared to the typical yield strength for most high-quality HDPE geocells, the above-referenced tensile forces are well within the elastic region for the material and any permanent deformation or “creep” over time is not expected, even when subject to cyclical traffic loads. Due to hoop stresses and earth pressures surrounding the loaded cells, there is no ability for the material to have any appreciable sustained deformation, and therefore, creep is not an issue.

The elastic response of the geocell-reinforced layer will ultimately be governed by the elastic properties of the infill material, and provided that suitable granular infill is used, the development of any significant strain in the cell walls will be heavily constrained by the effects of confinement of the granular material by the cell walls. The actual strain that develops in the cell wall will be significantly less than the amount of strain represented on a typical stress-strain curve generated from laboratory tests such as ISO 10319 or ASTM D4595 where samples are subjected to tensile forces in an unconfined state.

Development of hoop stress is essential for the proper engagement of the lateral confinement mechanism. Moreover, the ability to estimate hoop stresses under specific project circumstances can be useful as it allows engineers to develop a preliminary (and very conservative) understanding that tensile forces in the cell wall will remain within the elastic range for the material. It should be noted that many laboratory test methods such as ISO 10319 ignore the effects of confinement, and therefore, tend to overestimate strain levels that are outside of practical design conditions. Researchers who have completed laboratory and field test on geocells under applied loadings show that the strain in geocell walls is on the order of 0.2%. Evaluating material strength beyond reasonable strains is not relevant for sub grade reinforcement and the focus should be on strains less than 1.0%.

In general, provided the geocell is manufactured with a high-quality HDPE with a flexural storage modulus of at least 116 ksi (800 Mpa) and a 100-year durability rating (ISO 13438), the geocell can be expected to perform as intended throughout the service life of the project.

Geosystems’ Blog