
Neoloy Tough-Cell delivers a smarter, more sustainable alternative design National Grid National Grid Tough-Cell Tough-Cell Project Overview The project team needed to construct a durable compound on weak clay subgrade while meeting commercial, operational and long-term performance requirements. The project was being delivered for National Grid, with Balfour Beatty and ISC responsible for the construction works. Initially, the compound was designed using a geogrid solution. However, further engineering and commercial review identified an opportunity to significantly reduce project costs while also improving the sustainability credentials of the scheme. What began as involvement in one area of the compound ultimately expanded into a solution covering the wider compound works. Learn more about Neoloy Tough-Cell The Challenge The original design relied on a geogrid-reinforced construction that required imported aggregate. While technically viable, the solution presented a significant commercial challenge because of the cost and restrictions associated with the required stone materials. The project team identified that the real cost driver was not the geogrid itself, but the aggregate needed to make the system work. The site was founded on clay subgrade with a CBR of just 2.5%, requiring a robust ground improvement solution capable of supporting different loading requirements across the compound. In addition, the client sought a long-life asset that would require minimal maintenance throughout its operational life. Sustainability was also a key consideration. The team wanted a solution that could be removed at the end of the project's life without creating unnecessary landfill waste or leaving contaminated aggregate within the site. Traditional approaches offered limited opportunities for material separation and recycling once the asset reached the end of its service life. The Solution Neoloy Tough-Cell was introduced as an alternative to the original geogrid design. The system enabled the use of sand rather than the more expensive aggregate required by the geogrid solution. This immediately created a significant commercial advantage while maintaining the required performance of the construction platform. The solution also reduced the overall construction layer thickness compared with the original design and enabled one area that had originally been specified in concrete to be redesigned using Neoloy Tough-Cell. Rather than acting solely as a product supplier, PRS provided a complete package of support, including design, material supply, installation supervision and testing. The installation itself was self-delivered by ISC under PRS supervision, ensuring quality control while allowing the contractor to maintain control of site operations. Due to the success of this system, the scope expanded from the original section of the compound to the wider subcontracted compound area. The Outcome The Neoloy Tough-Cell solution delivered both engineering and commercial benefits for the project. Most significantly, the system was approximately 30% cheaper than the alternative geogrid solution. The savings were driven primarily by the ability to use lower-cost sand rather than imported aggregate. According to the project team, the financial advantage was so significant that the overall business case would still have favoured Neoloy Tough-Cell even if the competing geogrid had been supplied free of charge. Beyond the immediate cost savings, the solution delivered substantial sustainability benefits. The use of sand enabled clean segregation of materials at the end of the asset's life, allowing the Tough-Cell system to be recycled while avoiding contamination of the fill material. This reduced potential landfill waste and supported a more sustainable approach to construction. The reduced construction depth also helped lower imported material requirements and vehicle movements, reducing transport impacts associated with the project. Ultimately, the project demonstrated that the greatest value was achieved not by changing reinforcement products alone, but by rethinking the entire system design. By combining engineering expertise, technical support and a more efficient construction methodology, Tough-Cell provided a solution that was more economical, more sustainable and fully aligned with the project's long-term performance requirements. Read more about Neoloy Tough-Cell Latest News and Blogs Article Introducing Neoloy Tough-Cell: A smarter approach to ground stabilisation We're expanding our geocell offering through a new partnership with PRS, bringing the proven performance of Neoloy Tough-Cell to customers across the UK. Designed for challenging ground conditions, Neoloy Tough-Cell helps stabilise weak subgrades, improve load distribution and support more sustainable construction across a wide range of infrastructure projects. Jul 21, 2026 Case study Neoloy Tough-Cell delivers a smarter, more sustainable alternative design Neoloy Tough-Cell replaced a geogrid design, reducing costs, cutting carbon, simplifying construction and delivering stronger project value for all stakeholders. National Grid Read more Article Introducing the Civils Hub We've now opened the Civils Hub, our new customer experience centre, giving civil engineering professionals the opportunity to see, handle and better understand our geosynthetic solutions before specifying or installing them. Jul 6, 2026 Article Geoworks IQ: A new era of intelligent Geogrid design Introducing Geoworks IQ, our accessible design specification platform created to help users produce accurate, data-driven geogrid design specifications for haul roads. Jun 1, 2026 Share this page

Bulldozer filling cell in Neoloy Tough-Cell

Neoloy Tough-Cell delivers a smarter, more sustainable alternative design

National Grid
National Grid
Tough-Cell
Tough-Cell

Project Overview

The project team needed to construct a durable compound on weak clay subgrade while meeting commercial, operational and long-term performance requirements. The project was being delivered for National Grid, with Balfour Beatty and ISC responsible for the construction works.

Initially, the compound was designed using a geogrid solution. However, further engineering and commercial review identified an opportunity to significantly reduce project costs while also improving the sustainability credentials of the scheme. What began as involvement in one area of the compound ultimately expanded into a solution covering the wider compound works.

An open expanse of Neoloy Tough-Cell with construction vehicles in the background

Learn more about Neoloy Tough-Cell

The Challenge

Man stapling together Neoloy Tough-Cell panels

The original design relied on a geogrid-reinforced construction that required imported aggregate. While technically viable, the solution presented a significant commercial challenge because of the cost and restrictions associated with the required stone materials. The project team identified that the real cost driver was not the geogrid itself, but the aggregate needed to make the system work.

The site was founded on clay subgrade with a CBR of just 2.5%, requiring a robust ground improvement solution capable of supporting different loading requirements across the compound. In addition, the client sought a long-life asset that would require minimal maintenance throughout its operational life.

Sustainability was also a key consideration. The team wanted a solution that could be removed at the end of the project's life without creating unnecessary landfill waste or leaving contaminated aggregate within the site. Traditional approaches offered limited opportunities for material separation and recycling once the asset reached the end of its service life.

The Solution

Neoloy Tough-Cell was introduced as an alternative to the original geogrid design. The system enabled the use of sand rather than the more expensive aggregate required by the geogrid solution. This immediately created a significant commercial advantage while maintaining the required performance of the construction platform.

The solution also reduced the overall construction layer thickness compared with the original design and enabled one area that had originally been specified in concrete to be redesigned using Neoloy Tough-Cell.

Rather than acting solely as a product supplier, PRS provided a complete package of support, including design, material supply, installation supervision and testing. The installation itself was self-delivered by ISC under PRS supervision, ensuring quality control while allowing the contractor to maintain control of site operations.

Due to the success of this system, the scope expanded from the original section of the compound to the wider subcontracted compound area.

The Outcome

The Neoloy Tough-Cell solution delivered both engineering and commercial benefits for the project.

Most significantly, the system was approximately 30% cheaper than the alternative geogrid solution. The savings were driven primarily by the ability to use lower-cost sand rather than imported aggregate. According to the project team, the financial advantage was so significant that the overall business case would still have favoured Neoloy Tough-Cell even if the competing geogrid had been supplied free of charge.

Beyond the immediate cost savings, the solution delivered substantial sustainability benefits. The use of sand enabled clean segregation of materials at the end of the asset's life, allowing the Tough-Cell system to be recycled while avoiding contamination of the fill material. This reduced potential landfill waste and supported a more sustainable approach to construction.

The reduced construction depth also helped lower imported material requirements and vehicle movements, reducing transport impacts associated with the project.

Ultimately, the project demonstrated that the greatest value was achieved not by changing reinforcement products alone, but by rethinking the entire system design. By combining engineering expertise, technical support and a more efficient construction methodology, Tough-Cell provided a solution that was more economical, more sustainable and fully aligned with the project's long-term performance requirements.

Latest News and Blogs

Article

Introducing Neoloy Tough-Cell: A smarter approach to ground stabilisation

We're expanding our geocell offering through a new partnership with PRS, bringing the proven performance of Neoloy Tough-Cell to customers across the UK. Designed for challenging ground conditions, Neoloy Tough-Cell helps stabilise weak subgrades, improve load distribution and support more sustainable construction across a wide range of infrastructure projects.

Jul 21, 2026

Case study