The Sasan Coal Mines in Madhya Pradesh had periodic slope failures. TechFab India’s gabion toe walls provided a long-lasting, environmentally sustainable solution that improved safety and operational efficiency and ensured continuous coal output.

The Sasan Coal Mines in Madhya Pradesh, owned and operated by Sasan Power Ltd., is one of the largest coal mines in India.  The mining activity involves numerous open-cast mines, which generate significant amounts of waste annually. Continuous waste deposition has resulted in the construction of enormous, unstable dumps, which pose significant problems to mining operations and infrastructure. The height of the overburden dump could range from 20 to 40 metres at a sharp angle.

Heavy rainfall during the monsoon season exacerbates the instability of these waste dumps, leading to frequent slope failures along the roads accessing the mines. These landslides obstruct transportation, hinder mining activities, and pose safety risks to workers and equipment. The recurring subsidence has necessitated the implementation of advanced geotechnical solutions, such as slope stabilisation techniques and geosynthetic applications, to mitigate risks and ensure the sustainability of mining operations.

Addressing these difficulties is critical for preserving operating efficiency, improving overall safety, and assuring continuous coal production to meet nations’ demanding electricity needs.

To resolve this challenge, TechFab India proposed a comprehensive slope stabilisation solution involving the construction of Gabion Toe Walls at the base of the unstable slopes. A non-woven geotextile was placed behind the gabion walls to function as a filter and separator, preventing soil migration while allowing water drainage.

TechFab India’s solution was adopted due to the following key advantages:

· Durability and Flexibility: The gabion walls, made of high-strength galvanised steel mesh, offered a durable and flexible solution that could withstand dynamic environmental conditions.

· Eco-Friendly: The solution utilised natural stone-filled gabions, blending seamlessly with the environment and promoting vegetation growth over time.

· Quick Installation: Gabions ensure faster installation and completion than conventional structures.

· Cost-Effectiveness: The design of gabions enabled easy transportation, rapid installation, and minimal maintenance, making it a highly economical choice.

TechFab India successfully mitigated slope instability by implementing this engineered solution, ensuring a safe and sustainable outcome.

TechFab India’s gabion toe wall solution efficiently stabilised the slopes, reducing the frequency of failures on mine access roads. This ensured uninterrupted transit, improved worker safety, and increased operational efficiency. The long-lasting, eco-friendly, and cost-effective design ensured the sustainability of mining operations in Madhya Pradesh’s Sasan Coal Mines.

For more information, visit: https://www.techfabindia.com/