Bellary, Karnataka, India | JSW Steel Ltd, Bellary
JSW Steel Ltd.’s Vijayanagar Works, located in Toranagallu, Bellary, Karnataka, is one of India’s most advanced integrated steel manufacturing facilities. As part of its expansion, the construction of a new Hot Strip Mill (HSM) is already underway. The site also includes a newly constructed Blast Furnace (BF). However, there is a significant elevation difference of approximately 13 meters between these two structures – BF at 486m and HSM at 472.6m. To ensure the stability and safety of the ongoing Hot Strip Mill construction, slope protection measures must be implemented immediately to prevent erosion, soil movement, and potential failures that could impact the structural integrity and progress of the project.
The existing slope between the Blast Furnace and the Hot Strip Mill had a steep inclination of approximately 60 degrees with the horizontal and a total length of about 1,900 meters. Due to the significant height difference, this steep slope was vulnerable to erosion, soil movement, and potential failure caused by external loads, weathering, and construction activities. Without proper stabilization, there was a high risk of soil erosion, slope failure, and operational delays. To mitigate these risks, an engineered slope protection solution must be designed and implemented to ensure long-term stability, safety, and sustainability of the site, enabling smooth and secure construction of the Hot Strip Mill while maintaining the integrity of the Blast Furnace and surrounding infrastructure.
The client required a sustainable slope protection solution utilizing iron ore slag. Additionally, they emphasized the need for an environmentally friendly and aesthetically appealing solution. Due to these requirements, rigid retaining structures such as reinforced concrete walls and other conventional solutions were not feasible.
To fulfill the client’s needs, TechFab India proposed a Gabion retaining wall as the only viable solution. The design includes a 6.0m high TechFab Metal Gabion toe wall, utilizing iron ore slag as infill material. This modular, permeable, and durable structure effectively counteracts lateral soil pressure while ensuring long-term slope stability. Above the toe wall, the remaining 7.5m of the slope is protected using Geocell, which enhances erosion control, reinforces the soil, and improves overall structural integrity. This combined system provides a total slope protection height of 13.5m, ensuring a sustainable and resilient solution.
To enhance drainage and filtration, TechGeo Nonwoven Geotextile PR 20 was installed behind the gabion wall. This geotextile prevents soil migration while allowing water to pass through freely, thereby maintaining wall stability and preventing erosion.
The Gabion Wall not only provides a structurally robust solution but also integrates seamlessly with the surrounding landscape. The permeable nature of gabions allows water drainage, reducing hydrostatic pressure and preventing slope failure. To further enhance environmental sustainability, vegetation is introduced above the slope and along the offset of the retaining wall, reducing erosion and promoting a green ecosystem.
Phase 1 (Chainage 0+000 to 822+000) of this project was successfully completed and is performing as expected, meeting the satisfaction of both the client and contractor. This demonstrates TechFab India’s dedication to eco-friendly engineering solutions that ensure long-term slope stability, mitigate erosion risks, and facilitate smooth Hot Strip Mill construction. By incorporating Gabion Walls, Geocells, and Geotextiles, TechFab India provides a sustainable solution that seamlessly integrates durability, safety, and environmental harmony.
The site had a steep 13‑meter elevation difference between the newly constructed Blast Furnace and the Hot Strip Mill. Without stabilization, the slope was vulnerable to erosion, soil movement, and potential failure, which could disrupt construction and compromise structural safety.
The slope had a 60° inclination over 1,900 meters, making it highly prone to erosion and instability. Conventional rigid retaining structures were unsuitable due to cost, environmental concerns, and the client’s requirement for a sustainable, aesthetically pleasing solution.
TechFab India proposed a Green Gabion Wall System combined with Geocell reinforcement.
Geocell confines soil and aggregates, prevents erosion, reinforces the slope surface, and provides a stable base for vegetation, ensuring long‑term slope protection.
Phase 1 of the project was successfully completed, delivering long‑term slope stability and erosion control. The client was highly satisfied with the quality, timely execution, and eco‑friendly design, and the system is performing as expected.
By integrating gabions, geocells, and geotextiles into a sustainable slope protection system, TechFab India demonstrated its ability to deliver innovative, durable, and environmentally harmonious solutions for complex industrial infrastructure.
