BSL plant shuts down completely, 5k workers trapped inside complex

BOKARO: In an unprecedented crisis at BSL, a flagship unit of Steel Authority of India Limited (SAIL) and Asia's largest steel plant by area, all five blast furnaces at the plant have ceased operations on Friday, marking the first complete shutdown in its history. Plant veterans and senior officials confirmed that such a comprehensive production halt is unprecedented in BSL's operational history which started in the early 70s.
The situation has trapped approximately 5,000 employees inside the facility for over 30 hours, creating both a humanitarian crisis and an industrial emergency. A staggering production loss of 13,400 tonnes of hot metal within 24 hours has also been reported, causing significant financial implications for the Maharatna company.
According to the plant veterans and senior officials, the crisis began when protesters blocked all seven entry and exit points of the steel plant, effectively imprisoning the workers who had arrived for their B-shift on Thursday afternoon. The BSL management, supported by the Central Industrial Security Force (CISF), has been working to provide essential supplies to the stranded workforce, though many employees report challenging conditions inside.
SAIL chairman Amarendu Prakash is personally monitoring the situation with the Union steel ministry being kept informed of developments. In the absence of BSL's director-in-charge, Birendra Kumar Tiwary, who is currently in Delhi, the executive directors are managing the crisis on-site.
The shutdown has affected all major production units, including the coke oven, sinter plant, steel melting shop and hot strip mill. BSL chief of communications, Manikant Dhan, emphasized the critical nature of the situation, particularly the plant's complex gas pipeline network that requires constant monitoring for safety.
He said, "The current situation poses significant risks to both the facility and surrounding areas. Our thermo-sensitive operations and extensive gas pipeline network demand continuous oversight. The prolonged shutdown and staff constraints are making it increasingly difficult to maintain essential safety protocols."
Meanwhile, the plant management has issued urgent appeals to the protesters, highlighting the potential dangers of maintaining the blockade.
Unlike during the Covid-19 lockdowns when production was reduced to 50%, the current situation represents a complete operational shutdown, raising serious concerns about equipment integrity and safety systems.
Inside the facility, trapped employees are maintaining discipline despite difficult circumstances. Internal communication channels are being used to circulate messages, promoting calm and adherence to safety protocols. Support messages from colleagues outside the plant have helped maintain the morale among the stranded workers.
Experts said the crisis has broader implications for India's steel production capacity and industrial security protocols.