Typical applications Neoloy Tough-Cell is suitable for:
- Roads and pavements
- Rail infrastructure
- Ports and airports
- Working platforms
- Embankments
- Storage yards
Required equipment
Installation typically requires:
- Pneumatic stapler and galvanised staples
- Compressor and generator
- Stakes or anchors
- Standard earthworks and compaction equipment
- Geotextiles or geogrids where specified
Step 1 - Site preparation
Prepare the subgrade in accordance with the project drawings and specification. Remove vegetation, debris and unsuitable material before levelling and compacting the surface. Where specified, install geotextiles or geogrids with the required overlaps and seams.
Step 2 - Install anchor stakes
Install stakes along the alignment to secure the Neoloy Tough-Cell sections before expansion and infill. Typical spacing is approximately 500 mm depending on cell size and project requirements. Leave enough stake exposed for removal before compaction.
Step 3 - Layout Neoloy Tough-Cell sections
Lay folded Neoloy Tough-Cell sections in the direction of the road or pavement alignment before expanding them across the width of the installation area. Sections can be trimmed where required to suit the geometry of the project.
| Tough-Cell height |
Minimum staples |
| 75 mm |
3 |
| 100 mm |
4 |
| 120 mm |
4 |
| 150 mm |
5 |
| 200 mm |
6 |
Step 5 - Expand Neoloy Tough-Cell sections
Expand the sections over the anchor stakes until the cells reach their nominal dimensions and sit flush against the subgrade. Do not walk or drive directly on empty cells. Use boards where temporary access is required.
Step 6 - Place infill
Place the specified infill material evenly across the expanded sections. Maintain a minimum overfill of 70 mm above the cell walls before trafficking or compaction. Oversized debris or rock should be removed to prevent damage to the system.
Step 7 - Grading and compaction
Compact the infill in accordance with the project specification. Full compaction is critical to long-term performance. Where fill depths exceed 200 mm, compact in layers. Maintain a minimum cover of 20 mm above the cell walls after compaction.
Installation on curves
Neoloy Tough-Cell sections can be adjusted to suit curved alignments by varying the cell expansion. For tighter curves, tapered sections may be formed and fastened together to maintain consistent coverage and confinement.
Replacing damaged sections
Damaged sections can be removed and replaced locally without disturbing the wider installation. Replacement sections should be fully expanded, securely fastened and compacted using the same or higher-grade infill material.
Pre-installation checklist
Before installation begins, confirm:
- Approved drawings and specifications are available
- Neoloy Tough-Cell sections and infill materials are onsite
- Installation equipment is available and operational
- Geotextiles or geogrids are installed where required
- Installation personnel and QA supervision are in place
