Case Studies | SoilSmart Engineering — PRS Neoloy® Partner Projects

🇳🇬Road Design — Nigeria

Bonny Ring Road — PRS Neoloy® Pavement Design, Nigeria

Client: SoilSmart Engineering Ltd — Bonny Ring Road Project

SoilSmart Engineering Ltd designed a Neoloy Tough-Cells pavement solution for the Bonny Ring Road, demonstrating how the technology reduces total pavement thickness by 43% while using locally available sand infill on Nigerian subgrades.

Nigerian RoadPavement DesignLocal Sand InfillBonny Ring Road

Challenge

Conventional road design on Nigerian laterite subgrades requires costly multi-layer structures up to 625mm thick, with expensive crushed stone and cement-stabilised sand layers that are difficult to source and maintain in coastal and south-south terrain.

Solution

PRS Neoloy 330-120-C Tough-Cells (NPA composite) replace two layers entirely, reducing total structure to 355mm. Local sand is used as infill — no cement stabilisation required. Same or better performance at 43% lower thickness.

Outcome

Pavement design validated against ASTM D8269-21 and international Neoloy design methods (Prof. Jie Han, Univ. of Kansas). Construction cost reduced significantly. Local materials used throughout. Same CBR ≥5% subgrade acceptance.

🇺🇸Railway Stabilization

Track Subgrade Stabilization — Northeast Corridor, USA

Client: Amtrak / US DOT / Federal Railroad Administration

Amtrak specified PRS Neoloy Tough-Cells for soil stabilization on a problematic section of the Northeast Corridor near Havre de Grace, Maryland, where poor subgrade conditions caused rapidly deteriorating track geometry.

Railway StabilizationSoft SubgradePRS Neoloy Tough-CellsUSA

Challenge

Severe mud pumping and track geometry degradation from expansive clay subgrade under heavy dynamic loading on one of the busiest rail corridors in the USA.

Solution

A hybrid solution of Neoloy Tough-Cells with geogrid was implemented in the track substructure, selected for its very high tensile strength and long-term resistance to plastic and elastic deformation (creep resistance).

Outcome

PRS-Neoloy reinforcement proved effective, showing a reduction in the surfacing (maintenance) cycle on the order of seven (7) times — verified by Prof. Allan M. Zarembski, University of Delaware.

🇲🇽Airport Pavement

Asphalt Road Pavement — New International Airport, Mexico City

Client: Ancora Ingeniería — NAICM Mexico City International Airport

PRS Neoloy Tough-Cells were selected as the only qualified solution for stabilizing soft volcanic clay soils (CBR <1%) at the massive new Mexico City airport development after extensive field testing of alternative geosynthetics.

Airport PavementSoft ClayCBR <1%Mexico

Challenge

Highly problematic soft clay soils with CBR below 1% across the airport site made conventional pavement construction economically and technically unfeasible.

Solution

Neoloy Tough-Cells improved bearing capacity and modulus on soft soil using lightweight volcanic rock as infill for asphalt highway construction — more effective, economic, and faster than any other stabilization solution.

Outcome

"The PRS-Neoloy Tough-Cells was the only qualified solution that not only met, but exceeded, all our project requirements." — Eng. Mario Iruegas Evaristo, CEO, Ancora Ingeniería.

🇵🇱Heavy Port Pavement

Wharf Pavement Reinforcement — Gdansk Port, Poland

Client: STRABAG Sp. z o.o. — Port of Gdansk, Poland

STRABAG selected Neoloy Tough-Cells technology for the expansion of the Oliwskie Quay at the Port of Gdansk, due to its high modulus improvement factor, sustainability, quality, and economy.

Port PavementRecycled MaterialsSoft SubgradePoland

Challenge

Reconstruction of an old quay structure on soft, low-bearing organic subgrade requiring rigid, high-modulus reinforcement without expensive subgrade replacement.

Solution

Neoloy stabilized subbase using locally recycled sand infill from earthworks, providing sufficient reinforcement for heavy-duty recycled concrete pavement layers — eliminating the need for chemically stabilized subgrade.

Outcome

Significant cost savings using sustainable recycled materials. Rigid structure resistant to deformation delivered. STRABAG confirms and recommends Neoloy Tough-Cells in future projects.

🇬🇾Marine & Port Platform

Oil & Gas Shorebase Working Platform — Georgetown, Guyana

Client: Jan De Nul Group — Georgetown, Guyana

Jan De Nul needed to construct a working platform to build a new island for a mega-port project with oil & gas and commercial sections, without importing enormous amounts of expensive aggregate.

Oil & GasMarine PlatformWorking PlatformGuyana

Challenge

Remote coastal site with no viable aggregate supply. Platform required to support 800-ton construction cranes with minimal rutting, deflection, and differential settlements.

Solution

PRS Neoloy Tough-Cells validation enabled use of locally available sand for roads and the working platform. Engineering optimized pavements saving 92% in imported aggregate and reduced pavement thickness by 55%.

Outcome

Massive cost savings through local material use. Simplified logistics and fast installation. Working platform successfully supported 800-ton cranes throughout construction.

🇸🇸Humanitarian Infrastructure

Feeder Road Rehabilitation & Airstrip Expansion — South Sudan

Client: UNOPS / United Nations — South Sudan

The United Nations (UNOPS) selected PRS Geo-Technologies for infrastructure rehabilitation in South Sudan — including feeder roads across four states and expansion of the Rubkona airstrip — using Neoloy Geocell on highly problematic plastic black cotton soil.

Road RehabilitationBlack Cotton SoilHumanitarianUN South Sudan

Challenge

Roads largely impassable due to plastic black cotton soil subgrade, inadequate drainage, and years of neglect. Aggregate completely unavailable in the remote region.

Solution

Neoloy Geocell high-performance unpaved pavements built in 1/3 the time of conventional construction using locally available marginal soils — reducing pavement thickness by 25–40%.

Outcome

"Solutions provided by PRS Geo-Technologies could be replicated in other parts of the country... PRS demonstrated fast delivery, excellent technical support." — William Muchira, UNOPS.

🇬🇧Military Road Construction

Route Trident — Strategic Military Road, Helmand Province, Afghanistan

Client: UK Army — 28 Engineer Regiment, Royal Engineers

The British Army built a 9.2 km strategic supply route in Helmand Province under insurgent threat. PRS Neoweb (Neoloy) was selected for its ability to use local desert fill, reducing aggregate requirements by 75%.

Military RoadDesert TerrainWaterlogged SubgradeAfghanistan

Challenge

Fast construction under fire with limited budget, in saturated and desert terrain, with extremely expensive or unavailable crushed aggregate. Speed was critical to save lives.

Solution

Neoweb enabled a "floating" road on fully saturated ground using local desert fill (zero cost) for the semi-rigid sub-base, with aggregate only for the wearing course.

Outcome

Reduced road cost by 1/3. 75% less aggregate used. Road enables patrol bases to connect in under 30 minutes. Economic activity — shops, markets, schools — restarted in the region.

🇨🇦Industrial Working Platform

Sawmill Log Yard on Saturated Peat — British Columbia, Canada

Client: Confor Canada — British Columbia Sawmill

Confor's log handling yard on saturated peat soil (CBR=1%) repeatedly failed despite large gravel additions annually, preventing full operational capacity under heavy log handling equipment.

Industrial PlatformPeat SoilCBR=1%Canada

Challenge

Saturated peat subgrade with CBR of just 1%. Yard could not operate at full capacity. Seasonal downtime causing major production losses annually.

Solution

Dual layers of Neoloy — one on subgrade with sand infill to improve bearing capacity, and one in the base layer to increase modulus — transformed the yard completely.

Outcome

Yard manager estimated annual savings of $750 million from eliminated production losses and improved efficiencies, plus $250K in reduced vehicular fuel and maintenance costs.

🇿🇦Railway Track Rehabilitation

Track Stabilization for Freight Rail — South Africa

Client: Transnet — South African National Rail

Transnet adopted Neoloy as their solution of choice for rapid and reliable track stabilization of freight rail, rehabilitating subballast layers of coal car loading/unloading turnouts over soft soils.

RailwayFreight RailCoalSouth Africa

Challenge

Heavily loaded coal freight rail turnouts on soft subgrade requiring subballast layer rehabilitation. Maintenance cycles too frequent, causing operational disruptions.

Solution

Neoloy Tough-Cells reinforced the subballast layer of turnouts for heavily loaded coal cars over several years, validated by extensive testing and monitoring.

Outcome

Rapid installation reduced downtime. Stabilized track reduced maintenance cycles by 3–5×, verified by ongoing monitoring. Transnet adopted Neoloy as their preferred solution.

🇮🇱Port & Shipyard Platform

Heavy-Duty Shipyard Platform Reinforcement — Port of Haifa, Israel

Client: Israel Shipyards Ltd. — Port of Haifa, Israel

Israel Shipyards selected PRS Neoloy Tough-Cells for pavement rehabilitation of storage areas sustaining high concentrated loads of 400-ton cranes, replacing solutions that caused rutting and cracking.

ShipyardHeavy Crane LoadsPort InfrastructureIsrael

Challenge

Rutting, cracking, and voids forming in structural layers over the subgrade under 400-ton crane loads. Previous systems required frequent maintenance.

Solution

Neoloy reinforcement using local dredged sand as structural infill for concrete paving block surface. End-to-end service with PRS qualified engineers rehabilitated the shipyard 2× faster than predicted.

Outcome

"Since the installation of this product in 2012 we did not need to perform any maintenance services. We wholeheartedly recommend PRS Neoloy Geocells as the most cost-effective soil containment solution." — Shuki Sagy, VP, Israel Shipyards.

Proven Globally. Delivered in Nigeria.

Bonny Ring Road — PRS Neoloy® Pavement Design, Nigeria

Challenge

Solution

Outcome

Track Subgrade Stabilization — Northeast Corridor, USA

Challenge

Solution

Outcome

Asphalt Road Pavement — New International Airport, Mexico City

Challenge

Solution

Outcome

Wharf Pavement Reinforcement — Gdansk Port, Poland

Challenge

Solution

Outcome

Oil & Gas Shorebase Working Platform — Georgetown, Guyana

Challenge

Solution

Outcome

Feeder Road Rehabilitation & Airstrip Expansion — South Sudan

Challenge

Solution

Outcome

Route Trident — Strategic Military Road, Helmand Province, Afghanistan

Challenge

Solution

Outcome

Sawmill Log Yard on Saturated Peat — British Columbia, Canada

Challenge

Solution

Outcome

Track Stabilization for Freight Rail — South Africa

Challenge

Solution

Outcome

Heavy-Duty Shipyard Platform Reinforcement — Port of Haifa, Israel

Challenge

Solution

Outcome