EARTHLOK™ – Australia’s number one flexible concrete mat system, is changing the way mining projects approach erosion control — providing a cost-effective, long-term alternative to traditional rock-based protection methods such as rip rap and reno mattresses.
As the mining industry continues to navigate tighter budgets, stricter environmental standards, and increasing logistical constraints, the need for smarter ground stabilisation solutions is more urgent than ever.
With rock becoming harder to source, more expensive to transport, and prone to failure in the long term, Earthlok is fast becoming the product of choice for asset owners and engineers seeking permanent erosion control with minimal lifecycle costs.
At Hazelwood coal mine in Victoria, Earthlok has been deployed across over 50,000 m² of critical slopes and drainage infrastructure as part of the site’s large-scale rehabilitation program.
In one standout example, a 3,500 m² catch drain was completed in just 1.5 days — a drastic improvement over the originally specified
reno mattress solution, which would have taken six to eight weeks and required large quantities of imported rock.
The system required minimal ground preparation, no rock sourcing, and has required virtually no maintenance since installation.
“Hazelwood showcased the speed, efficiency, and reliability of Earthlok under challenging conditions,” says Sarah Woolley, GeneralManager at Earthlok.
“The ability to cover large areas quickly — without relying on quarry supply chains — was a game changer for the project team.”Another major success came at former Alcoa Anglesea Mine and Power Station, also in Victoria.Faced with the challenge of designing for a 1-in-100-year storm event, the original solution called for rocks up to a metre in diameter in major drainage channels.
Instead, Earthlok was selected for its hydraulic performance, cost advantages, and installation speed. The result: a resilient system that eliminated the need for imported rock, finished ahead of schedule, and has remained intact and maintenance-free through significant rain events.
Earthlok has also been deployed in remote, tropical conditions atRio Tinto’s Gove operations in the Northern Territory, where steepterrain and heavy wet season rainfall posed a threat to a key culvertand adjoining slopes.
Earthlok was selected for its ability to provide a robust, permanent barrier against erosion, and its efficiency in remote terrain.
The system has now withstood multiple wet seasons and continues to protect critical infrastructure in one of Australia’s harshest environments.
In Queensland, at the Ironbark site currently operated by FitzroyAustralia Resources, Earthlok was installed to protect high-flow spillways.
The product’s rapid deployment and long-term durability allowed the project to be completed quickly and cost-effectively, supporting uninterrupted site operations and reducing contractor time on site.
“These are just a handful of examples of Earthlok in action,” saysWoolley. “We’re seeing increasingly strong demand from mining operations looking for engineered, low-maintenance solutions that provide whole-of-life value — particularly in applications like spillways, batter chutes, embankment protection, culvert outlets, and mine closure works.”
Earthlok has also been used at several Rio Tinto sites in thePilbara, Tallison Lithium (WA), Whitehaven (NSW), Loy Yang –AGL (Vic), Yallourn – Energy Australia (Vic) amongst others.
Earthlok’s performance and value are matched by practical benefits: it is manufactured locally, easy to transport, conforms to irregular ground, and can be installed rapidly with minimal preparation. Combined with in-house design support and on-site training, Earthlok ensures project success from start to finish.
INTRODUCING GEOLOK™ – A SMARTER GEOCELL FORMINE SITE REINFORCEMENT
To further support ground stabilisation needs on mine sites, Earthlok has launched GEOLOK™ — Australia’s first mortise tendon geocell system.
Unlike traditional welded HDPE geocells, GEOLOK™ features a mechanical interlock that enhances strength, simplifies assembly, and performs reliably under heavy loads.
GEOLOK™ is engineered for applications such as haul roads, working platforms, access tracks, slope reinforcement, and soft ground improvement.
It offers superior confinement, consistent spacing, and resistance to shear deformation — key advantages where surface stability and load distribution are critical. “This is a step-change for ground improvement,” Woolley explains.
“GEOLOK™ takes geocell performance to the next level —delivering the strength and installation efficiency the mining sector has been waiting for.”
