Ernakulam, Kerala, India | Greenland Particle Boards Pvt Ltd.
Greenland Particle Boards Private Limited, a leading manufacturer of wood-based particle boards in India, is located in Perumbavoor, Ernakulam District, Kerala. During the development of a new building within the factory premises, a critical failure occurred in the existing stone masonry retaining wall, which was originally constructed to support the surrounding terrain. The wall, ranging from 6 to 7 meters in height and extending approximately 58 meters, suffered a collapse over a 40 – 45 meter stretch due to a sudden surge in loading.
The failure was attributed to excessive pressure caused by the presence of heavy construction machinery, large stockpiles of building materials, and increased workforce activity. The sudden surge in load surpassed the structural capacity of the stone masonry retaining wall, leading to its failure. The proximity of the superstructure, located just 11 meters away, heightened the risk of further structural compromise, making an immediate and effective solution imperative.
The potential failure of the stone masonry retaining wall could impact the foundation of the adjacent structure, potentially leading to the failure of the superstructure. Therefore, replacing the existing retaining wall with a sustainable and cost-effective solution was a top priority and needed to be executed promptly. This solution needed to ensure long-term resilience, cost-effectiveness, and ease of construction while mitigating further risks and reinforcing the foundation for ongoing and future developments at the site. A well-engineered solution was essential to withstand future load surges, enhance site safety, and provide a durable, low-maintenance alternative capable of adapting to varying ground conditions and environmental factors.
After analyzing the situation and urgency of the project, TechFab India proposed a Gabion Gravity Retaining Wall as a replacement for the failed stone masonry retaining wall. The proposed wall heights were 7m (6m AGL + 1m embedment depth) and 8m (7m AGL + 1m embedment depth).
Gabion gravity retaining walls are one of the quickest and most economical solutions for sudden retaining wall failures in a short period. Their flexible, permeable, and durable nature makes them highly suitable for soil retention and structural protection. The gabions, constructed using woven wire mesh baskets filled with locally available boulders, offer both structural integrity and cost efficiency. Additionally, gabion construction is fast and can be executed using unskilled labor, further reducing costs and ensuring swift completion.
To enhance drainage and filtration, TechGeo Nonwoven Geotextile PR 25 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.
This solution not only met technical demands for slope stabilization and erosion control but also aligned with the environmental and aesthetic needs of the region. Most importantly, the project was completed in a short time, ensuring minimal disruption to factory operations and safeguarding adjacent infrastructure.
The project was successfully completed in June 2024, before the monsoon, and is performing as intended to the satisfaction of both the client and contractor. This reflects TechFab India’s commitment to eco-friendly engineering solutions that ensure structural stability while preserving the environment.
The existing stone masonry retaining wall (6–7 m high, 58 m long) collapsed over a 40–45 m stretch due to sudden surge in loading from construction machinery, stockpiled materials, and workforce activity. This posed a serious risk to the nearby superstructure located just 11 m away.
Risk of superstructure failure due to compromised foundation support.
Need for a quick, cost-effective, and sustainable solution.
Requirement to withstand future load surges.
Ensuring long-term resilience while minimizing disruption to factory operations.
TechFab India proposed a Gabion Gravity Retaining Wall:
Heights of 7 m (6 m AGL + 1 m embedment) and 8 m (7 m AGL + 1 m embedment).
Constructed using woven wire mesh gabion baskets filled with locally available boulders.
TechGeo Nonwoven Geotextile PR25 installed behind the wall for filtration and drainage.
Flexible, permeable, and durable design suitable for soil retention and erosion control.
Flexibility to adapt to ground movements.
Permeability, allowing water to drain and reducing hydrostatic pressure.
Durability with wire mesh and boulder infill.
Faster construction using unskilled labor, reducing costs.
Environmentally friendly and aesthetically compatible with surroundings.
Quick installation, ideal for urgent replacement projects.
Cost-effective compared to rigid masonry or concrete walls.
Low maintenance with long service life.
Provides structural stability and erosion control.
Sustainable and eco-friendly engineering solution.
Project completed successfully in June 2024, before monsoon season.
Retaining wall is performing effectively, ensuring slope stability and protecting adjacent infrastructure.
Minimal disruption to factory operations.
Client satisfaction with durability, sustainability, and timely execution.
TechFab Metal Gabions
TechGeo PP Nonwoven Geotextile PR25
