Versicell: The Innovative Modular Lattice Product for Drainage, Retention, Erosion Control

Introduction to Versicell

Versicell is an innovative product used in landscape and engineering projects as an alternative to traditional fill materials. Made from recycled plastic, Versicell provides strength, drainage, and porosity in a lightweight and modular system. Versicell has many advantages for building retaining walls, slope stabilization, tree pits, driveway foundations, and more. Keep reading to learn all about versicell and how it can benefit your next project.

What is Versicell?

Versicell is a three-dimensional geo-grid comprised of interlocking lattice panels made from recycled High Density Polyethylene (HDPE). The panels connect together like Lego blocks to form a porous and strong structural system. Versicell was invented in 2003 as a solution for supporting and stabilizing weak soils in a variety of applications. It is now manufactured and distributed worldwide by Versicell Systems with their corporate headquarters located in Russellville, Arkansas.

Benefits of Versicell

Versicell offers a number of benefits that make it advantageous over traditional fill materials like gravel, sand, or soil:

• Lightweight - Versicell panels weigh only 1/10th as much as gravel or soil, reducing transportation costs.
• Strong - The interlocking panels create a cohesive structural grid that can support heavy loads.
• Drainage - Up to 95% void space allows water drainage and prevents pooling or erosion.
• Porosity - Water, air, and plant roots can penetrate the open lattice structure.
• Modular - Panels connect easily for any size or shape needed.
• Sustainable - Made from 100% recycled plastic that diverts waste from landfills.
• Cost-effective - Lower material and labor costs compared to traditional backfill methods.

These characteristics make versicell an efficient and Earth-friendly solution for many infrastructure and landscaping jobs. The material is also inert and will not degrade over time like wood or other organic materials.

Composition of Versicell

Versicell panels are made completely from post-consumer recycled High Density Polyethylene (HDPE) plastic. This plastic is derived primarily from used milk jugs and water bottles collected in recycling programs. The reclaimed HDPE plastic is heated, extruded, and molded into the Versicell panels.

Each versicell panel measures approximately 24 inches x 15 inches x 4 inches (60cm x 40cm x 10cm). Panels easily connect together with interlocking edges that do not require any special tools. No glues, pins, zip ties, or extras are needed. The lightweight panels simply stack together through integrated connectors.

Versicell is inert and 100% resistant to biological, chemical, and electrochemical degradation. It will not rot, warp, split, crack or dissolve when exposed to soil, water, salt, or UV light. This durability ensures the versicell system will last for decades underground.

Applications for Versicell

With its light weight and high strength, versicell can be used in place of traditional backfill materials for many infrastructure and landscaping applications. Here are some of the most common uses for versicell:

Retaining Walls

Versicell is exceptionally well suited for building retaining walls up to over 30 feet high. The lattice structure provides internal stability and drainage behind the wall facing. This removes pressure and allows thinner wall dimensions compared to old style "stacked rock" walls. Versicell retaining walls can be designed with various ecological facing options like stone, concrete, wood, or gabions (wire cages).

Slope Stabilization

Unstable slopes prone to erosion, landslides, or washouts can be effectively stabilized with versicell. The panels anchor into the slope like rebar, preventing downhill movement. Versicell retains soil strength while allowing proper drainage through the slope. This application often uses versicell in conjunction with geotextile fabrics anchored by earth percussion anchors.

Tree Pit Surrounds

Versicell provides an ideal urban environment for tree root growth and pavement support when installed underneath sidewalks, driveways, or parking areas around a tree pit. The voids encourage deep root penetration while preventing soil compaction that harms trees. Versicell transfers surface loads down through the porous grid, protecting tree roots from crushing weight above.

Driveways and Roads

Constructing driveways, rural roads, parking areas, equipment yards, and work platforms over soft soils is made easy with a versicell base. The lattice bears and distributes vehicle weight while preventing rutting failures common with gravel or dirt surfaces. Versicell fills can be installed faster than traditional backfill and road base methods.

Utility Bedding

Versicell provides an engineered fill option for bedding and encasing underground utilities like electrical conduits, gas lines, water pipes, and sewer drains. The grid structure surrounds pipes evenly and prevents settling while allowing proper drainage. In cold climates, versicell helps prevent frost heaving commonly seen under paved utility trenches.

Golf Bunker Liners

Versicell makes an ideal liner for golf course bunkers below the sand layer. The open structure allows water drainage to prevent puddles while blocking underlying soils from mixing into the clean bunker sand. Versicell bunker liners also resist burrowing animal damage seen with traditional geotextile fabrics.

Stormwater Detention

Versicell can be used to create underground stormwater detention systems to manage urban rainwater runoff. Water easily flows into the versicell lattice then drains out slowly over time. This application requires additional engineering to calculate storage volume and drainage rates.

Installing Versicell Systems

Installing versicell is relatively simple compared to traditional backfill methods. Here is an overview of the key installation steps:

Site Preparation

The native soil foundation needs to be graded smooth and compacted to 95% standard proctor density to create a stable base. Any debris, organics, or large rocks must be removed. Geotextile filter fabric is placed over the prepared subgrade.

Leveling

The first layer of versicell panels are placed and leveled on top of the filter fabric. Top surfaces must be flat and even before stacking additional layers.

Stacking

Panels are stacked upward by interlocking the connector knobs into receptor slots on adjoining panels. A staggered stack pattern ensures structural integrity. Built-in spacers provide a consistent 1/8" gap between panel walls.

Facing

Once the versicell is stacked to full height, aesthetic facings or coverings are installed as desired. Common options are natural stone, modular block, shotcrete, or soil covering with vegetation.

Finishing

Final site elements are put in place, such as railings, lights, pavement, landscaping, or other finishes. Versicell provides a stable and level substructure for quality results.

Proper installation according to manufacturer specifications ensures the versicell system performs as designed. Always consult the manufacturer's guidelines or an experienced versicell installer for your specific project.

Versicell Brands and Variations

While Versicell Systems holds the original versicell patents and remains the most prominent producer, there are now a few other brands offering similar products. Various versicell-like geo-grids exist under names like MegaCell, StrataCell, GeoRidge, and TerraLock among others. While not exact copies, these provide alternatives with comparable properties. Aside from branded variations, versicell itself comes in a few modified options:

VersiGreen

VersiGreen has the same panel structure as original versicell but with wider vertical gaps ideal for grass or plant growth. The expanded openings allow greater soil intrusion and root penetration while maintaining the lattice strength. VersiGreen is popular for greenscape walls or grass paving systems.

VersiJack

VersiJack offers larger and stronger modular panels for heavy duty applications. The tall column-beam structure interlocks together like gigantic jacks. VersiJack provides enhanced compressive, tensile, and shear strength capable of supporting tremendous static and dynamic loads.

VersiLite

This ultra lightweight versicell option uses thinner panels made from a composite of foamed HDPE and fiberglass. VersiLite is 75% lighter than standard versicell while retaining most of the strength. The exceptional light weight helps reduce shipping costs and enables new lifting applications.

It's important to note versicell is designed as a composite system. The products generally need to be purchased from a licensed producer rather than sourced from independent panel manufacturers. Verify you are getting authentic versicell before purchase.

Costs, Codes, and Availability

Versicell provides many construction and landscaping advantages at competitive costs compared to traditional backfill techniques. However, site-specific factors impact exact pricing. Here is an overview of cost considerations as well as codes and availability:

Cost Factors

The installed price per cubic foot is affected by:

• Material, shipping, and labor rates for your region
• Soil conditions requiring geo-fabrics or drainage
• Panel strength and depth required
• Size of project
• Complexity of configuration
• Cap and facing options

Bulk orders or multi-project contracts can reduce costs through volume discounts. Experienced product distributors can provide estimating tools to calculate price ranges specific to your unique project.

Building Codes

Most jurisdictions approve the use of versicell for retaining walls and various applications as an acceptable alternative to traditional backfill. However, some may require an engineering approval or stamped drawings. Check with your local building department regarding any special guidelines or restrictions in your area.

Sourcing Versicell

Versicell maintains an international distribution network, so their products are available widely through various landscape supply stores, geosynthetic material suppliers, and construction contractors. You can source versicell through local dealers in many regions, or order direct from the Versicell Systems factory.

For best results, look for experienced versicell installation contractors in your area. The manufacturer may provide referrals. This expertise ensures proper handling and build quality for optimal system performance.

DIY Installation Tips

Ambitious do-it-yourselfers can install small residential versicell projects on their own. Here are some tips for DIY success:

• Study the manufacturer installation guides thoroughly before starting.
• Follow local building codes for permits and engineering approvals.
• Ensure you have a compacted and level soil base.
• Work incrementally in 1-2 foot stacked sections with alignment guides.
• Backfill gradually and compact after each layer.
• Monitor for panel buckling or shifting during backfilling.
• Select facade options you can handle like dry stack stone or modular blocks.
• Take time to place facing materials neatly and attractively.

While manageable for low, small projects, versicell requires precision that may be challenging for homeowners without construction experience. Consider hiring a professional versicell contractor for more substantial installations to ensure lasting quality and safety.

Comparable Products

While versicell remains the premier product, a few alternatives offer similar functioning geo-grid solutions:

MegaCell

Made by GreenBlue Urban, MegaCell uses recycled HDPE to create a versicell-like porous lattice in larger panel sizes. MegaCell is used primarily for stormwater detention systems under parking lots or pavement.

StrataCell

StrataCell is made from perforated thermoplastic panels assembled into a 3D stratified matrix. StrataCell can be installed with automated equipment for rapid pipeline or utility trench backfilling.

GeoRidge

Produced by TenCate Geosynthetics, GeoRidge is a HDPE lattice-grid substitute for angular drainage rock. GeoRidge is used for retaining walls, bridge abutments, streambeds, and similar applications.

TerraLock

TerraLock provides interlocking aluminum panels that connect together like versicell. TerraLock is lightweight and fast to install but higher cost than the recycled HDPE options.

Each product has unique characteristics, strengths, and best uses. Consult with an engineering firm or landscaping contractor to determine which option may suit your specific needs and budget.

Future Outlook

Versicell gained rapid market adoption after its invention and continues gaining momentum as more engineers, architects, and contractors recognize the performance benefits compared to traditional backfill methods. While versicell alternatives exist, Versicell Systems retains the lion's share of the geo-grid market.

Looking ahead, versicell stands positioned for increased growth driven by several trends:

• Demand for cost-effective infrastructure and landscaping solutions
• Preference for lightweight, modular systems
• Need for water management and drainage
• Desire for sustainable and green building practices
• Creative new design applications

With its versatility and proven field results, versicell seems poised for continued expansion worldwide. Specifying versicell demonstrates your commitment to quality, strength, sustainability, and cutting edge building science.

Conclusion

Versicell offers a game-changing alternative to traditional earthwork backfill for a broad range of infrastructure and landscaping applications. The recycled modular plastic panels create a porous lattice providing strength, stability, and drainage in a lightweight and easy-to-install system.

With benefits like reduced costs, faster construction, smaller carbon footprint, and improved performance, versicell continues revolutionizing how we approach site preparation and structure support. This innovative product offers an Earth-friendly and cost-effective option for architects, engineers, contractors, and property owners looking to maximize value and mitigate risk on their next project.

FAQs

What is versicell made of?

Versicell is made completely from post-consumer recycled High Density Polyethylene (HDPE) plastic collected from recycling programs. The plastic is heated, extruded, and molded into interlocking lattice panels.

How does versicell connect together?

Versicell panels feature knobs and receptor slots that interlock together without requiring any pins, zip ties, adhesives or special tools. The panels stack together by hand like Lego blocks.

Is versicell suitable for large retaining walls?

Yes, versicell can be used to build retaining walls over 30 feet high. The rigid lattice structure provides exceptional strength and drainage capacity for tall wall applications.

Does versicell require engineering approval?

Some municipalities may require an engineer's approval or stamped plans for larger versicell installations. Check with your local building department regarding permit requirements.

What are the main advantages of versicell?

The key benefits of versicell are its light weight, strength, porosity, modularity, sustainability, drainage, and cost-effectiveness compared to traditional backfill methods.