Soil Stabilization with Gabion Boxes in Shujalpur Mandi, Madhya Pradesh

Project overview

Ocean Non Wovens supplied 240 gabion boxes for a soil stabilisation project in Shujalpur Mandi, Madhya Pradesh. Each box measured 1 metre in height and 2 metres in length and was filled with locally sourced stone. The work was meant to hold the soil in place, control monsoon erosion and protect existing structures on the site.

The site

Shujalpur is a market town in Shajapur district on the Malwa plateau. The surrounding land is mostly farmland with uneven ground, and the black cotton soils common in the region soften and wash out easily in heavy monsoon rain. Erosion here damages both fields and the structures built on them.

Ocean Non Wovens was asked for a way to stabilise the soil, stop erosion and protect what was already built. After a site assessment, the team chose stone-filled gabions over a rigid wall.

How gabion boxes stabilise soil

A gabion is a wire mesh box filled with stone. Laced together, the boxes act as a gravity structure: their weight holds back the soil behind them. They do three jobs on a site like this:

• Erosion control: The rough, porous stone face absorbs the energy of flowing water, so runoff loses its power to scour soil.
• Slope support: The mass of the stone resists soil movement and slips.
• Drainage: Water passes straight through the stone fill, so hydrostatic pressure does not build up behind the structure the way it can behind a solid wall.

Because the mesh can flex, a gabion wall tolerates some uneven settlement without cracking. In India, double-twisted hexagonal mesh gabions are covered by IS 16014. Where fine soil sits directly behind a gabion, a non-woven geotextile is often placed between the soil and the stone as a filter, so water drains out but soil particles stay put.

Installation

1. Site preparation: Vegetation and debris were cleared to give the gabions a stable base.
2. Foundation layer: A compacted soil base provided a level surface for the boxes.
3. Placement: The boxes were set out in a staggered pattern and joined to form a continuous barrier. Staggering the joints, as in brickwork, avoids straight vertical seams that would weaken the structure.
4. Filling: Each box was packed with stone, keeping voids to a minimum so the box holds its shape. Fill stone is normally larger than the mesh opening so it cannot work its way out.
5. Settling: The fill was packed down after placing to reduce later settlement.

Challenges on site

• Fill material: Stone was sourced locally, which kept haulage costs down.
• Monsoon: Rain made site access and material handling harder. Planning the work around the weather kept delays in check.
• Variable soil: Soil types changed across the site, so the installation was adjusted section by section to keep the structure uniformly stable.

Results

• Soil stability: The gabions stabilised the soil and reduced the risk of erosion and slips.
• Drainage: Water drains freely through the stone fill, which prevents waterlogging behind the structure.
• Cost: Local stone and modular boxes kept the cost down compared with a cast concrete wall.
• Environment: Natural stone fill and a porous face let vegetation and silt settle into the structure over time.

Working with Ocean Non Wovens

Ocean Non Wovens checks its gabion boxes for quality before dispatch, sizes them to suit site conditions and client requirements, and supports clients after installation. To discuss gabions or other soil stabilisation products for your project, contact us, or see more of our case studies.