The increasing generation of ash from coal-fired thermal power plants necessitates sustainable disposal strategies, particularly in mining regions where space constraints pose challenges. This study has evaluated the feasibility of integrating pond ash with overburden dumps in a large opencast coal mining project. A comprehensive assessment was carried out, incorporating field studies, route and traffic analyses, time-motion studies, and equipment performance evaluations. Key challenges identified include increased traffic congestion from ash-hauling operations, inefficiencies in mixing and dozing, and geotechnical stability concerns, particularly under wet conditions. The study also explores transportation alternatives, highlighting the cost-effectiveness of rail transport, though constrained by infrastructure, and the flexibility of road transport, albeit with congestion and safety risks. Seasonal variations, especially rainfall, were found to exacerbate dump stability concerns and runoff contamination. A detailed analysis of effect on production due to mixing of ash with overburden for an active coal mine is also presented in this paper. The study underscores the importance of strategic planning to accommodate ash with overburden mining operations.