Co-developing a smarter gravel grid for sustainable outdoor infrastructure

As demand for sustainable outdoor infrastructure solutions continues to grow across Europe, DW Reusables and MAKS Products joined forces to further develop an innovative gravel grid system.

Combining MAKS Products’ market expertise with DW Reusables’ engineering and manufacturing capabilities, the two companies co-developed a solution focused on long-term durability, easier installation, and efficient transport.

The project demonstrates how close collaboration can transform practical market insights into high-performance products for professional landscaping and infrastructure applications.

Gravel grids are increasingly used as an alternative to traditional concrete surfaces for driveways, pathways, parking areas, and other outdoor applications. By allowing rainwater to infiltrate naturally into the soil, they contribute to more sustainable water management and help reduce surface runoff.

However, these applications place high demands on the product itself.

The grids need to withstand continuous exposure to sunlight, moisture, frost, and temperature fluctuations while remaining strong enough to support both passenger vehicles and heavy traffic. At the same time, they must remain lightweight, easy to install, and efficient to transport.

Together, MAKS Products and DW Reusables set out to improve installation efficiency, structural performance, and long-term sustainability without compromising ease of use.

Working closely together, the engineering teams of DW Reusables and MAKS Products analysed the existing honeycomb structure and introduced several targeted improvements.

One of the key innovations was the integration of a high-quality geotextile layer underneath the grid. This prevents weeds from growing through the gravel while still allowing rainwater to infiltrate naturally into the ground. Because installers no longer need to apply a separate root barrier, installation becomes faster and more efficient.

The grids are produced using 100% polypropylene copolymer (PPC), selected for its excellent resistance to UV radiation, moisture, frost, and changing weather conditions.

To optimise structural strength while maintaining flexibility and lightweight handling, the injection moulding process was carefully engineered using sixteen injection points to ensure an optimal material flow throughout the honeycomb structure.

The combination of different hexagon sizes further improves load distribution while simplifying production and ensuring consistent product quality.

The redesigned gravel grid delivers clear benefits for installers, distributors, and end users alike.

The integrated geotextile significantly reduces installation time while maintaining excellent water permeability. The lightweight construction remains easy to transport and handle, while the dimensions are optimised for efficient transport on standard Europallets.

Despite weighing only 1.54 kg per unit, the grid provides exceptional load-bearing capacity once filled, making it suitable for demanding applications such as driveways, parking areas, and access roads.

Thanks to the durable PPC material, the grids offer long-term resistance against sunlight, frost, and weathering, ensuring reliable outdoor performance for many years. Available in grey and white, they blend naturally into outdoor environments while supporting sustainable landscaping projects.

At the end of their lifecycle, the grids are fully recyclable, contributing to a more circular approach to outdoor infrastructure.

This project demonstrates the value of true co-development.

By combining MAKS Products’ market knowledge with DW Reusables’ engineering and manufacturing expertise, both companies developed a solution that responds directly to the practical challenges faced by installers and end users.

Rather than creating a standard product, the project focused on continuous collaboration, translating real-world experience into technical improvements that deliver measurable value in everyday applications.

The result is an innovative gravel grid that combines performance, ease of installation, and long-term sustainability.

MAKS Products is a specialist in innovative solutions for paving and landscaping across Belgium and the Netherlands. The company supplies gravel stabilisation systems, resin-bound solutions, edging products, and other outdoor infrastructure materials, helping professionals create durable and sustainable outdoor environments.

We combine technical expertise, industry knowledge, and genuine collaboration to create reusable packaging solutions that perform in your operations today and evolve with your needs tomorrow.