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Neoloy Tough-Cell

Neoloy Tough-Cell geocells deliver high-performance 3D confinement for roads, rail, compounds, working platforms and heavy-duty infrastructure applications.

Unlike traditional stabilisation methods, Tough-Cell enables the use of alternative, recycled and locally available infill materials, helping to significantly reduce aggregate demand, minimise settlement and lower overall construction costs and resources.

Neoloy Tough-Cell installation

Advanced ground stabilisation for weak subgrades and heavy loads

Weak subgrades, rising aggregate costs and increasing sustainability pressures are changing how infrastructure projects are designed. Traditional construction methods often rely on large volumes of imported, well graded aggregate to achieve stability, particularly in poor ground conditions. This increases excavation, haulage and overall construction costs.

Tough-Cell provides a more efficient approach to stabilisation by confining infill within a high-strength three-dimensional cellular structure. This improves load distribution, reduces lateral movement and creates a stiffened reinforcement layer that increases bearing capacity while helping minimise settlement under repeated loading.

Unlike conventional planar stabilisation systems, Tough-Cell can also accommodate a wider range of infill materials, including lower-grade aggregates, recycled materials and locally sourced fill. This reduces dependence on expensive processed stone and creates opportunities to lower both material costs and embodied carbon.

The result is a more efficient pavement structure that can reduce imported aggregate requirements, improve long-term performance and support more sustainable construction across roads, rail, working platforms and heavy-duty infrastructure applications.

Man stapling together Neoloy Tough-Cell panels

Products

Stock code Description My Geoworks Downloads
GC/TOUGH/120/330 Tough-Cell 120mm Cell Height, 2.5m x 8.0m expanded cell size, 330mm distance between weld seams
GC/TOUGH/150/330 Tough-Cell 150mm Cell Height, 2.5m x 8.0m expanded cell size, 330mm distance between weld seams
Neoloy Tough-Cell installation with construction vehicles on site

Why choose Tough-Cell?

Tough-Cell is engineered to deliver high-performance ground stabilisation in demanding environments where conventional systems can struggle. Its three-dimensional confinement structure improves load distribution, reduces aggregate requirements and enables the use of alternative infill materials, helping contractors and designers achieve more efficient and cost-effective construction solutions.

Stronger confinement

3D confinement restricts movement in all directions, helping improve bearing capacity and structural performance.

Enables alternative infill

Can utilise sand, recycled aggregate and locally available lower-grade materials.

Reduces settlement

Helps minimise rutting and differential settlement under repeated loading.

Lower construction costs

Reduces imported aggregate, haulage and overall pavement build-up requirements.

Sustainable construction

Supports lower-carbon construction by reducing quarrying and material transport.

Long-term performance

Engineered for heavy-duty applications with high stiffness and creep resistance.

Proven engineering benefits

Tough-Cell’s three-dimensional confinement structure delivers measurable performance improvements compared with conventional stabilisation approaches. By restricting lateral movement within each cell, the system creates a stiffer, more stable load-bearing layer that improves stress distribution across weak ground conditions.

These benefits allow designers to achieve required performance levels using thinner construction profiles and lower-cost fill materials, even in challenging ground conditions. The result is a more efficient use of materials, reduced aggregate demand and lower overall construction carbon.

reduction in pavement layer thickness.

Up to 80%

lower settlements under load.

Up to 80%%

improvement in layer modulus.

Up to 5x

reduction factory in comparative thickness testing.

Up to 70%+

Tough-Cell project enquiry

Tough-Cell delivers high-performance ground stabilisation for roads, rail, working platforms and heavy-duty infrastructure projects. Complete the enquiry form and our technical team will assess your project requirements, ground conditions and performance objectives to recommend the most efficient and cost-effective solution.

  • Current Project details
  • Performance criteria
  • Delivery model
  • Your information
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Application
Will the unpaved area require removal?

Applications

Suitable for demanding infrastructure projects

Tough-Cell delivers high-performance ground stabilisation wherever weak subgrades, heavy loading and challenging site conditions threaten long-term performance. Its three-dimensional confinement structure creates stronger, more stable surfaces while reducing aggregate demand and enabling the use of alternative infill materials.

Road construction, haul road or highway embankment

Road construction often encounters weak ground, poor bearing capacity and rising aggregate costs. Tough-Cell reinforces the pavement structure by confining infill materials within a three-dimensional cellular system, helping reduce rutting, improve load distribution and create more durable road foundations.

Crane pad, piling rig or construction platform

Heavy plant and construction equipment demand stable working surfaces capable of supporting high loads. Tough-Cell increases bearing capacity and helps minimise settlement, creating safer, more reliable working platforms even in challenging ground conditions.

Storage yard, logistics compound or industrial hardstanding

Strong, durable surfaces are essential for compounds, laydown areas and operational yards. Tough-Cell confines aggregate and distributes loads more effectively, helping reduce surface degradation and maintain performance under constant vehicle movements and stored materials.

Rail access road, maintenance compound or trackside works

Rail projects frequently require access routes and working areas across weak or variable ground conditions. Tough-Cell provides ground reinforcement that improves stability, reduces aggregate requirements and supports efficient construction and maintenance operations.

Wind farm access road, solar farm or substation development

Renewable energy and utility projects are often located in remote areas with difficult ground conditions. Tough-Cell creates stable access roads and working areas while reducing reliance on imported aggregate, supporting more efficient and sustainable construction.

Container yard, freight terminal or port infrastructure

Ports and logistics facilities are subjected to frequent heavy loading from HGVs, containers and handling equipment. Tough-Cell strengthens load-bearing layers, helping reduce settlement and maintain long-term surface performance in demanding operational environments.

Neoloy Tough-Cell installation

Confinement vs Stabilisation

Most conventional stabilisation systems rely on interlock between aggregate particles and a planar reinforcement layer. To perform properly, these systems typically need well graded, high-quality aggregates with tightly controlled particle sizes. That requirement drives up material costs because the aggregate must go through additional screening, crushing and processing before it reaches site.

Tough-Cell works differently.

Its three-dimensional confinement structure restricts aggregate movement within each individual cell, creating a stiffened structural layer that distributes loads more effectively across weak subgrades. Rather than depending purely on particle interlock across a flat plane, the confinement mechanism physically contains the fill material, reducing lateral spread and maintaining structural integrity under load.

This difference is significant because it opens up the range of materials that can be used within the system.

Where conventional geogrid solutions often require expensive, well graded stone, Tough-Cell can accommodate lower-cost alternatives including less refined aggregates, site-won materials and, in some applications, even sand. That is a major distinction; traditional stabilisation systems generally cannot achieve the same performance using these materials because they lack the three-dimensional confinement needed to control movement effectively.

The commercial impact can be substantial. On some projects, using locally sourced or minimally processed fill materials has reduced aggregate costs to roughly one third of those associated with premium graded stone. With aggregate prices continuing to rise, particularly for processed materials transported over long distances, the ability to use alternative fills creates a clear economic advantage.

There are environmental benefits as well. Reducing reliance on quarried and heavily processed aggregates lowers embodied carbon, cuts transport movements and enables greater reuse of materials already available on site. For projects in remote locations, areas with poor access, or sites where imported stone is prohibitively expensive, this can materially improve project viability while reducing overall construction impact.

Bulldozer pushing reclaimed site materials over Neoloy Tough-Cell
Reduce carbon save cost

Reduce imported aggregate and utilise on-site materials

One of the key advantages of Tough-Cell is its ability to work with lower-cost infill materials, including:

  • Sand
  • Marginal fill
  • Recycled aggregate
  • Recycled asphalt (RAP)
  • Recycled concrete
  • Locally won granular materials

This reduces dependency on imported virgin aggregate and helps minimise haulage, fuel usage and environmental impact.

Related case studies

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.

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National Grid
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